Professional Documents
Culture Documents
SX TRANSISTOR CONTROL
Page 1
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 November 1999
Section 1.0
INTRODUCTION ........................................................................................................................................................ 4
1.1
1.2
1.3
1.4
Section 2.0
Performance.............................................................................................................................. 6
Oscillator Card Features .................................................................................................. 6
Standard Operation .................................................................................................. 6
Creep Speed............................................................................................................... 6
Controlled Acceleration and 1A Time..................................................................... 6
Current Limit ...................................................................................................................... 6
Braking ............................................................................................................................... 6
Plug Braking .............................................................................................................. 6
Regenerative Braking to Zero Speed ...................................................................... 6
November 1999
2.1.3.c
2.1.3.d
2.1.3.e
2.1.4
2.1.4.a
2.1.4.b
2.1.5
2.1.5.a
2.1.5.b
2.1.6
2.1.7
2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.3
2.3.1
2.3.2
2.3.2.a
2.3.2.b
2.3.3
2.3.3.a
2.3.4
2.3.4.a
2.3.5
2.3.6
2.3.6.a
2.3.7
2.3.8
2.4
Section 3.0
Section 4.0
Page 2
November 1999
Page 3
Section 6.0
DASH DISPLAYS....................................................................................................................................................... 64
7.1
7.2
7.3
7.4
7.5
Section 8.0
Section 7.0
MEMORY MAPS........................................................................................................................................................ 66
8.1
Page 4
SPEED
TORQUE
ARMATURE CURRENT
Figure 2
STARTING
CURRENT
FULL
LOAD CURRENT
NO LOAD CURRENT
SPEED
STARTING
CURRENT
FULL
LOAD CURRENT
NO LOAD CURRENT
Section 1. INTRODUCTION
SPEED
STARTING
CURRENT
NO LOAD CURRENT
ARMATURE CURRENT
Figure 1
FULL
LOAD CURRENT
TORQUE
TORQUE
ARMATURE CURRENT
Figure 3
Page 5
LINE POS
FUSE
Q3
Q5
A1 +
ARM
CAP
Q2
F1
F2
A2 Q4
Q1
NEG
Figure 4
Q6
Page 6
Page 7
=
=
=
Look ahead
Look again
Automatic look again and reset
The PMT circuit will not allow the control to start under the
following conditions:
=
=
November 1999
Page 8
Page 9
November 1999
SX TRANSISTOR CONTROL
IC3645
01
Argument 01:
Argument 02:
Control Type:
SP
SH
SR
Argument 03:
D
04
33
05
2
06
C3
07
=
=
=
=
120 volts
24 volts
36 volts
72/80 volts
4
5
6
=
=
=
48 volts
36/48 volts
24/36 volts
Package Size:
D
R
U
W
Argument 05:
=
=
=
4
03
Operating Voltage:
1
2
3
7
Argument 04:
SE
02
=
=
=
=
6.86
6.86
8.66
8.66
X
X
X
X
6.67
8.15
8.13
10.83
Armature Current
( 2 characters )
22
33
40
etc.
=
=
=
220 Amps
330 Amps
400 Amps
Argument 06:
Field Current
( 1 character )
2
=
20 Amps
3
=
30 Amps
4
=
40 Amps
etc.
Argument 07:
Customer / Revision
A1
B1
etc.
=
=
Customer A / Revision 1
Customer B / Revision 1
November 1999
Page 11
November 1999
Page 12
November 1999
PUMP CONNECTION
BATT NEG
TMM7
FU4
LINE
FU5
44
TMM7
STEER PUMP
ARM
SP
89
A2
88
A1
43
FU1
NEG
A1
F1
PUMP
CONNECTION
POS
A2
F2
CONTROL POWER
CONNECTION
POS
KEY SWITCH
A1
F1
A2
F2
FIELD
FU3
13A
29
P7
P1
P18
60
10
P17
24
SP
P6
BRAKE
SWITCH
P3
P4
*
ACCEL
START
SWITCH
15
50
PY8
P5
BDI INTERRUPT
FWD REV
* CUSTOMER SUPPLIED
PUMP TMM
PUMP TMM
PY9
DIRECT
SWITCH
MOTOR CONNECTIONS
FOOT BRAKE
SWITCH
P13 P10
ACCEL
SW.
P2
10
10
BRAKE
SWITCH
SX TRANSISTOR CONTROL
Page 13
November 1999
ARMATURE
LINE
CONTACTOR
BATT (-)
5A
FU2
P
A1
A2
A2
A1
PUMP CONTROL
POWER CONNECTION
12-1
A2
A1
3
4
5
6
8
9
15
16
11
13
14
SX-2
CONTROL PLUG PL2
13C
SPEED 4
53
52
13C
*
*
TO TRACTION
PL2-10
13C
51
50
13C 13C
21
20
19
12
10
SPEED 2
FU6
SPEED 1
10
PY1
PY2
PY4
PY3
TRACTION CONTROL
NEGATIVE
PY5
PY1
PY2
PY4
PY3
1 2 3 4 5
DASH DISPLAY
5 4 3 2 1
SHIELDED
CABLE
SEE NOTE
SUPPLIED BY CUSTOMER
POWER CONNECTION
NOTE:
COVER SHIELDED CABLE WITH HEAT
SHRINKABLE TUBING (NO CONNECTIONS)
ACCELERATOR
SWITCH
TRACTION CARD
PUMP CARD
KEY SW.
ARMATURE
FIELD
SPEED 3
SHIELDED
CABLE
SEE NOTE
SX TRANSISTOR CONTROL
Page 14
November 1999
SX TRANSISTOR CONTROL
Section 3.6 Traction and Pump Control Input and Output List
CONNECTIONS TO MAIN PLUG (23 PIN) AND "Y" PLUG (12 PIN)
PIN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
PIN
1
2
3
4
5
6
7
8
9
10
11
12
TRACTION
INPUT/OUTPUT DESCRIPTION
BATTERY VOLTS FROM BATTERY
BATTERY VOLTS FROM KEY
BATTERY VOLTS FROM START SWITCH
BATTERY VOLTS FROM FORWARD SWITCH
BATTERY VOLTS FROM REVERSE SWITCH
BATTERY VOLTS FROM BRAKE SWITCH
ACCELERATOR INPUT VOLTAGE SIGNAL
NOT USED
ACCELERATOR POT +5 VOLTS SUPPLY
BDI INTERRUPT
PLUG/RGN OUTPUT SIGNAL +12V 1=PLUG
NOT USED
FOOT BRAKE SWITCH
NOT USED
NOT USED
NOT USED
LINE CONTACTOR DRIVER AND SUPPRESSION
STEER PUMP CTR DRIVER AND SUPPRESSION
NOT USED
NOT USED
NOT USED
SERIAL RECEIVE / DASH DISPLAY
SERIAL TRANSMIT / DASH DISPLAY
MOTOR PROPORTIONING "Y" PLUG
INPUT/OUTPUT DESCRIPTION
CLOCK (OUT)
DATA (OUT)
ENABLE (OUT)
NEGATIVE
+5V SUPPLY
CONT/STORE (IN) (HANDSET)
NOT USED
VALUE
FUNCTION
NOT USED
SERIAL RECEIVE / CONNECT TO P22
SERIAL TRANSMIT / CONNECT TO P23
2
9
10
11
3
10
4
11
5
12
PUMP
INPUT/OUTPUT DESCRIPTION
BATTERY VOLTS FROM BATTERY
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
SPEED LIMIT #4 INPUT
SERIAL RECEIVE
SERIAL TRANSMIT
PUMP "Y" PLUG
INPUT/OUTPUT DESCRIPTION
CLOCK (OUT)
DATA (OUT)
ENABLE (OUT)
NEGATIVE
+5V SUPPLY
CONT/STORE (IN) (HANDSET)
NOT USED
VALUE
FUNCTION
NOT USED
SERIAL RECEIVE / CONNECT TO P22
SERIAL TRANSMIT / CONNECT TO P23
6
13
6
14
8
15
12
16
17
18
19
20
21
22
23
November 1999
SX TRANSISTOR CONTROL
to verify that the contactors are not binding and that the
tips are intact and free of contaminants.
GE does not recommend that any type of welding be
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
SX TRANSISTOR CONTROL
=
=
=
=
November 1999
SX TRANSISTOR CONTROL
2.
3.
Che
-R-C
Pow H Z
s
Wa
e
zan
ciro
Figure 1
4.
B
LU
N
A
IC
R
TS
1.
ye
N
n ic s
r
ane
t cle
tac
con
mt r o
Figure 2
5.
Reconnect plugs.
Reference
Cleaner
Chemtronics
Cleaner
Pow-R-WasH CZ Contact
Lubricant
Nye
Lubricants NYOGEL
328A1777G1
760G
SX TRANSISTOR CONTROL
November 1999
SX TRANSISTOR CONTROL
TRACTION
STATUS CODE
NONE
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS
Segments do not illuminate on the
Dash Display and/or the Handset.
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Display screen on Dash Display and/or Handset
is blank.
POSSIBLE CAUSE
Positive or negative control voltage is not
present.
= 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.
= Check for an open circuit or loose connection
going from the control and the Dash Display or
Handset.
KEY
SWITCH
FU3
FU5
P2
P1
NEG
TRACTION
STATUS CODE
-01
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS
No brake switch or deadman switch
input (no voltage to P6).
CORRECTIVE ACTIONS
SYMPTOM
Control will not operate.
TROUBLE-SHOOTING DIAGRAM
KEY SWITCH
10
POSSIBLE CAUSE
Mis-adjusted or defective brake or deadman
switch.
= Check to see that the brake switch closes
properly.
Open circuit between battery positive and P6.
= Check for loose connections or broken wires:
= Between the brake switch and P6
= Between the key switch and the battery
positive side of the brake switch.
= Between the brake switch and P2.
BRAKE
SWITCH
BRAKE
SWITCH
*
DIRECT
SWITCH
10
SP
FWD REV
L
10
60
24
P18
P1
P17
P2
P6
*
ACCEL
START
SWITCH
15
8
PUMP TMM
P3
P4
November 1999
P5
PY9
SX TRANSISTOR CONTROL
TRACTION
STATUS CODE
-02
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate because of Static Return
to Off (SRO) lock out.
KEY SWITCH
10
POSSIBLE CAUSE
Forward directional switch is closed on initial
start up (i.e. closure of battery, key switch or
brake switch).
= Return directional switch lever to neutral and
then return lever to forward position.
BRAKE
SWITCH
BRAKE
SWITCH
*
DIRECT
SWITCH
10
SP
FWD REV
L
10
60
24
P18
P17
8
PUMP TMM
P3
P6
P2
*
ACCEL
START
SWITCH
15
P4
P5
PY9
P1
TRACTION
STATUS CODE
-03
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate because of Static Return
to Off (SRO) lock out.
KEY SWITCH
10
POSSIBLE CAUSE
Reverse directional switch is closed on initial
start up (i.e. closure of battery, key switch or
brake/deadman switch).
= Return directional switch lever to neutral and
then return lever to reverse position.
BRAKE
SWITCH
BRAKE
SWITCH
*
DIRECT
SWITCH
10
SP
FWD REV
L
10
60
24
P18
P1
P17
P2
P6
*
ACCEL
START
SWITCH
15
8
PUMP TMM
P3
P4
P5
PY9
SX TRANSISTOR CONTROL
TRACTION
STATUS CODE
-05
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS
Start switch fails to close.
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
BRAKE
SWITCH
KEY SWITCH
POSSIBLE CAUSE
Defective brake switch circuit.
= Check brake 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.
Defective accelerator switch.
= Check accelerator switch potentiometer for
proper operation and ohmic value.
10
BRAKE
SWITCH
*
DIRECT
SWITCH
10
SP
FWD REV
L
60
10
24
P18
P7
P17
P2
P6
*
15 ACCEL 6
START
SWITCH
P3
P4
PUMP TMM
P5
PY9
ACCEL
SW.
TRACTION
STATUS CODE
-06
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS
Accelerator depressed with no
direction selected.
CORRECTIVE ACTIONS
SYMPTOM
Control will not operate.
TROUBLE-SHOOTING DIAGRAM
10
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.
Defective directional switch
= Check forward or reverse switch to insure
closure when direction is selected.
Open circuit between directional switch(es) and
battery positive or between directional switch(es)
and P4 or P5.
= Check all control wires and connections shown
in Trouble Shooting Diagram.
BRAKE
SWITCH
KEY SWITCH
BRAKE
SWITCH
*
DIRECT
SWITCH
10
SP
FWD REV
L
60
P18
P7
10
24
P17
P2
P6
*
15 ACCEL 6
START
SWITCH
P3
P4
ACCEL
SW.
November 1999
P5
PUMP TMM
PY9
SX TRANSISTOR CONTROL
TRACTION
STATUS CODE
-07
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS
Accelerator voltage too high on power
up after initial key switch closure.
CORRECTIVE ACTIONS
SYMPTOM
Control will not operate when accelerator pedal
is depressed or status code -07 is displayed
then disappears when the vehicle starts to
accelerate.
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.
Open circuit between battery negative and P7 in
accelerator input circuit.
= Check for broken wires or loose connections
or open potentiometer / voltage supply.
TROUBLE-SHOOTING DIAGRAM
P9 P7
NEGATIVE
ACC POT
TRACTION
STATUS CODE
-08
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS
Accelerator input voltage too low on
power up after initial key switch
closure.
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
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.
P9 P7
NEGATIVE
ACC POT
November 1999
SX TRANSISTOR CONTROL
TRACTION
STATUS CODE
-09
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS
Both the forward and reverse
directional switches are closed at the
same time.
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
10
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
P18
P7
P17
P2
P3
P4
PUMP TMM
P5
PY9
ACCEL
SW.
TROUBLE-SHOOTING DIAGRAM
BRAKE
SWITCH
KEY SWITCH
Defective control.
= Disconnect wire from P3. Measure voltage
from P3 to negative. Voltage should be zero,
if not, replace control.
P6
*
15 ACCEL 6
START
SWITCH
SYMPTOM
Control will not operate.
10
24
CORRECTIVE ACTIONS
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.
*
DIRECT
SWITCH
FWD REV
DESCRIPTION OF STATUS
Start switch closed on power up after
initial key switch closure.
BRAKE
SWITCH
10
Defective Control
= Disconnect wires and measure voltage at P4
and P5. Voltage should be less than 60% of
battery volts.
-11
SP
60
TRACTION
STATUS CODE
BRAKE
SWITCH
KEY SWITCH
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.
10
BRAKE
SWITCH
*
DIRECT
SWITCH
10
SP
FWD REV
L
60
P18
P7
10
24
P17
P2
P6
*
15 ACCEL 6
START
SWITCH
P3
P4
ACCEL
SW.
November 1999
P5
PUMP TMM
PY9
SX TRANSISTOR CONTROL
TRACTION
STATUS CODE
-15
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS
Battery voltage is too low or control
card is mis-adjusted.
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
FU5
POSSIBLE CAUSE
Discharged battery
= Check battery for proper open circuit voltage
as shown in Trouble Shooting Diagram,
charge battery, if required.
Defective battery
= Check each battery cell for proper voltage
(greater than 1.95 volts at cell). Replace or
repair battery.
NOMINAL
BATTERY
VOLTAGE
MINIMUM
LIMIT VOLTS
AT 1.95 VDC
PER CELL
24
23.4
36
35.1
48
46.8
72
80
70.2
78.0
P1
NEG
TRACTION
STATUS CODE
-16
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS
Battery voltage is too high or control
card is mis-adjusted.
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
FU5
POSSIBLE CAUSE
Incorrect control card adjustment
Check Function 15 for proper adjustment for
battery being used. See Handset instructions
for details. Adjust to proper setting.
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.
NOMINAL
BATTERY
VOLTAGE
MINIMUM
LIMIT VOLTS
AT 1.95 VDC
PER CELL
24
23.4
36
35.1
48
46.8
72
80
70.2
78.0
P1
November 1999
SX TRANSISTOR CONTROL
TRACTION
STATUS CODE
-23
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
TRACTION
STATUS CODE
-24
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS
Motor field current is high on start up in
the reverse direction.
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Defective control.
= Replace controller unit.
DESCRIPTION OF STATUS
Motor field current is high on start up in
the forward direction.
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
BRAKE
SWITCH
KEY SWITCH
10
POSSIBLE CAUSE
Defective control.
= Replace controller unit.
BRAKE
SWITCH
*
DIRECT
SWITCH
10
SP
FWD REV
L
60
P18
P7
10
24
P17
P2
P6
*
15 ACCEL 6
START
SWITCH
P3
P4
ACCEL
SW.
November 1999
P5
PUMP TMM
PY9
SX TRANSISTOR CONTROL
TRACTION
STATUS CODE
-27
MEMORY RECALL
YES
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Line contactor opens and closes, then can only
be closed by opening and closing the key
switch.
KEY
SWITCH
FU3
FU5
POSSIBLE CAUSE
Discharged Battery
= Check battery to insure proper state of charge.
Voltage may be dropping below 10 Volts DC
under load.
P2
P1
NEG
Defective control.
= Replace controller unit.
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
FU3
* SWITCH
3 KEY
BRAKE SWITCH
*
10
SP
POSSIBLE CAUSE
Continued operation of vehicle in
high motor current condition.
=
Operate vehicle at lower motor
current condition for 70
seconds.
60
* ACCEL
START
7 15 SWITCH 6
29
*
FU4
* FU1
TMM7 43
88
+
A1
*
POS A1 F1
A2 CONTROL POWER
CONNECTION
TMM7 89
NEG A2 F2
*
44
PUMP
TMM
P18 P17 P2
P6 P3 P4
P5 PY9
OSC CARD CONNECTIONS
P1
P13 P10
P7
PY8
PUMP
CONNECTION
POS
LINE
FWD
REV
10
24
FU5
BRAKE SWITCH
DIRECT SWITCH
*
*
A1
F1
*
F2
SP
PUMP TMM
ACCEL SWITCH
Circuits valid
for
Traction
Controller
CORRECTIVE
ACTIONS
ARMATURE
YES
FIELD
MEMORY RECALL
STEER PUMP
ARM
-28
DESCRIPTION OF STATUS
PUMP CONNECTION
BATT NEG
TRACTION
STATUS CODE
50
13A
*
*
FOOT
BRAKE
SWITCH
A2
November 1999
BDI
INTERRUPT
SX TRANSISTOR CONTROL
YES
Circuits valid
for
Traction
Controller
CORRECTIVE
ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Reduced or no power to traction
motor in control range.
FU3
* SWITCH
3 KEY
BRAKE SWITCH
*
10
SP
L
POSSIBLE CAUSE
Control is in thermal cut-back.
= Allow control to cool, status
code should disappear.
60
BRAKE SWITCH
DIRECT SWITCH
*
*
FWD
REV
10
24
* ACCEL
FU5
7 15
LINE
Defective control.
= Replace controller unit.
29
A1
STEER PUMP
ARM
PUMP CONNECTION
BATT NEG
PUMP
TMM
PUMP TMM
FU4
* FU1
TMM7 43
88
+
A1
*
POS A1 F1
A2 CONTROL POWER
CONNECTION
TMM7 89
NEG A2 F2
*
44
START
SWITCH
P18 P17 P2
P5 PY9
P6 P3 P4
OSC CARD CONNECTIONS
P1
P13 P10
P7
PY8
PUMP
CONNECTION
POS
ACCEL SWITCH
MEMORY RECALL
F1
ARMATURE
-41
DESCRIPTION OF
STATUS
FIELD
TRACTION
STATUS CODE
BDI
INTERRUPT
50
13A
*
*
F2
SP
FOOT
BRAKE
SWITCH
A2
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
FU3
* SWITCH
3 KEY
BRAKE SWITCH
*
10
SP
POSSIBLE CAUSE
Defective control.
= Replace controller unit.
60
FWD
REV
10
24
* ACCEL
FU5
7 15
29
*
FU4
* FU1
TMM7 43
88
+
A1
*
POS A1 F1
A2 CONTROL POWER
CONNECTION
TMM7 89
NEG A2 F2
*
44
START
SWITCH
PUMP
TMM
P18 P17 P2
P5 PY9
P6 P3 P4
OSC CARD CONNECTIONS
P1
P13 P10
P7
PY8
PUMP
CONNECTION
POS
LINE
BRAKE SWITCH
DIRECT SWITCH
*
*
A1
F1
*
F2
SP
PUMP TMM
ACCEL SWITCH
Circuits valid
for
Traction
Controller
CORRECTIVE
ACTIONS
ARMATURE
NO
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.
FIELD
MEMORY RECALL
STEER PUMP
ARM
-42
DESCRIPTION OF
STATUS
PUMP CONNECTION
BATT NEG
TRACTION
STATUS CODE
50
BDI
INTERRUPT
13A
*
*
FOOT
BRAKE
SWITCH
A2
November 1999
SX TRANSISTOR CONTROL
-43
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF
STATUS
Motor armature offset
voltage is too low.
CORRECTIVE
ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
FU3
* SWITCH
3 KEY
BRAKE SWITCH
DIRECT SWITCH
*
*
BRAKE SWITCH
*
10
SP
POSSIBLE CAUSE
Defective control.
= Replace controller unit.
60
FWD
REV
10
24
* ACCEL
FU5
7 15
LINE
29
*
A1
ARMATURE
F1
FIELD
STEER PUMP
ARM
PUMP CONNECTION
BATT NEG
FU4
* FU1
TMM7 43
88
+
A1
*
POS A1 F1
A2 CONTROL POWER
CONNECTION
TMM7 89
NEG A2 F2
*
44
START
SWITCH
PUMP
TMM
P18 P17 P2
P5 PY9
P6 P3 P4
OSC CARD CONNECTIONS
P1
P13 P10
P7
PY8
PUMP
CONNECTION
POS
PUMP TMM
ACCEL SWITCH
TRACTION
STATUS CODE
50
BDI
INTERRUPT
13A
*
FOOT
BRAKE
SWITCH
F2
SP
A2
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Line contactor opens and closes,
then can only be closed by opening
and closing the key switch.
FU3
* SWITCH
3 KEY
BRAKE SWITCH
*
10
SP
L
60
POSSIBLE CAUSE
Defective control.
= Replace controller unit.
FWD
REV
10
24
* ACCEL
START
7 15 SWITCH 6
FU5
29
*
FU4
* FU1
TMM7 43
88
+
A1
*
POS A1 F1
A2 CONTROL POWER
CONNECTION
TMM7 89
NEG A2 F2
*
44
PUMP
TMM
P18 P17 P2
P5 PY9
P6 P3 P4
OSC CARD CONNECTIONS
P1
P13 P10
P7
PY8
PUMP
CONNECTION
POS
LINE
BRAKE SWITCH
DIRECT SWITCH
*
*
A1
F1
*
F2
SP
PUMP TMM
ACCEL SWITCH
Circuits valid
for
Traction
Controller
CORRECTIVE
ACTIONS
ARMATURE
YES
FIELD
MEMORY RECALL
STEER PUMP
ARM
-44
DESCRIPTION OF
STATUS
PUMP CONNECTION
BATT NEG
TRACTION
STATUS CODE
50
13A
*
*
FOOT
BRAKE
SWITCH
A2
November 1999
BDI
INTERRUPT
SX TRANSISTOR CONTROL
-45
MEMORY RECALL
YES
Circuits valid
for
Traction
Controller
DESCRIPTION OF
STATUS
Armature transistor did not
turn on properly.
CORRECTIVE
ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Line contactor opens and closes,
then can only be closed by
opening and closing the key
switch.
FU3
* SWITCH
3 KEY
BRAKE SWITCH
*
10
SP
L
60
FWD
REV
10
24
* ACCEL
FU5
POSSIBLE CAUSE
Defective control.
= Replace controller unit.
7 15
29
*
F1
*
ARMATURE
A1
FIELD
STEER PUMP
ARM
PUMP CONNECTION
BATT NEG
FU4
* FU1
TMM7 43
88
+
A1
*
POS A1 F1
A2 CONTROL POWER
CONNECTION
TMM7 89
NEG A2 F2
*
44
START
SWITCH
PUMP
TMM
P18 P17 P2
P5 PY9
P6 P3 P4
OSC CARD CONNECTIONS
P1
P13 P10
P7
PY8
PUMP
CONNECTION
POS
LINE
BRAKE SWITCH
DIRECT SWITCH
*
*
PUMP TMM
ACCEL SWITCH
TRACTION
STATUS CODE
50
BDI
INTERRUPT
13A
*
*
F2
SP
FOOT
BRAKE
SWITCH
A2
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Line contactor will not pick up.
FU3
* SWITCH
3 KEY
BRAKE SWITCH
*
10
SP
L
POSSIBLE CAUSE
Check for short circuit from the
motor armature to the frame of
the vehicle.
60
FWD
REV
10
24
* ACCEL
FU5
7 15
LINE
29
*
FU4
* FU1
TMM7 43
88
+
A1
*
POS A1 F1
A2 CONTROL POWER
CONNECTION
TMM7 89
NEG A2 F2
*
44
START
SWITCH
PUMP
TMM
P18 P17 P2
P5 PY9
P6 P3 P4
OSC CARD CONNECTIONS
P1
P13 P10
P7
PY8
PUMP
CONNECTION
POS
Defective control.
= Replace controller unit.
BRAKE SWITCH
DIRECT SWITCH
*
*
A1
F1
*
F2
SP
PUMP TMM
ACCEL SWITCH
Circuits valid
for
Traction
Controller
CORRECTIVE
ACTIONS
ARMATURE
NO
FIELD
MEMORY RECALL
STEER PUMP
ARM
-46
DESCRIPTION OF
STATUS
PUMP CONNECTION
BATT NEG
TRACTION
STATUS CODE
50
BDI
INTERRUPT
13A
*
*
FOOT
BRAKE
SWITCH
A2
November 1999
SX TRANSISTOR CONTROL
-49
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF
STATUS
Motor field current is too low
during the run mode.
CORRECTIVE
ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
FU3
* SWITCH
3 KEY
BRAKE SWITCH
DIRECT SWITCH
*
*
BRAKE SWITCH
*
10
SP
POSSIBLE CAUSE
Defective control.
= Replace controller unit.
60
FWD
REV
10
24
* ACCEL
FU5
7 15
PUMP
CONNECTION
POS
LINE
29
*
A1
ARMATURE
F1
FIELD
STEER PUMP
ARM
PUMP CONNECTION
BATT NEG
FU4
* FU1
TMM7 43
88
+
A1
*
POS A1 F1
A2 CONTROL POWER
CONNECTION
TMM7 89
NEG A2 F2
*
44
START
SWITCH
PUMP
TMM
P18 P17 P2
P5 PY9
P6 P3 P4
OSC CARD CONNECTIONS
P1
P13 P10
P7
PY8
PUMP TMM
ACCEL SWITCH
TRACTION
STATUS CODE
50
BDI
INTERRUPT
13A
*
FOOT
BRAKE
SWITCH
F2
SP
A2
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Line contactor does not close when
capacitor does not precharge.
FU3
* SWITCH
3 KEY
BRAKE SWITCH
*
10
SP
L
60
* ACCEL
START
7 15 SWITCH 6
Defective control.
= Replace controller unit.
29
*
FU4
* FU1
TMM7 43
88
+
A1
*
POS A1 F1
A2 CONTROL POWER
CONNECTION
TMM7 89
NEG A2 F2
*
44
PUMP
TMM
P18 P17 P2
P5 PY9
P6 P3 P4
OSC CARD CONNECTIONS
P1
P13 P10
P7
PY8
PUMP
CONNECTION
POS
LINE
FWD
REV
10
24
FU5
POSSIBLE CAUSE
Defective control fuse.
= Check control fuse for open circuit.
Replace fuse, if necessary.
BRAKE SWITCH
DIRECT SWITCH
*
*
A1
F1
*
F2
SP
PUMP TMM
ACCEL SWITCH
Circuits valid
for
Traction
Controller
CORRECTIVE ACTIONS
ARMATURE
NO
FIELD
MEMORY RECALL
STEER PUMP
ARM
-51
DESCRIPTION OF
STATUS
PUMP CONNECTION
BATT NEG
TRACTION
STATUS CODE
50
13A
*
*
FOOT
BRAKE
SWITCH
A2
November 1999
BDI
INTERRUPT
SX TRANSISTOR CONTROL
-57
MEMORY RECALL
YES
Circuits valid
for
Traction
Controller
DESCRIPTION OF
STATUS
Controller motor current
sensor input too low during
running.
CORRECTIVE
ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
FU3
* SWITCH
3 KEY
BRAKE SWITCH
DIRECT SWITCH
*
*
BRAKE SWITCH
*
10
SP
POSSIBLE CAUSE
Defective control.
= Replace controller unit.
60
FWD
REV
10
24
FU5
7 15
29
*
A1
ARMATURE
F1
FIELD
STEER PUMP
ARM
PUMP CONNECTION
BATT NEG
FU4
* FU1
TMM7 43
88
+
A1
*
POS A1 F1
A2 CONTROL POWER
CONNECTION
TMM7 89
NEG A2 F2
*
44
START
SWITCH
P18 P17 P2
P5 PY9
P6 P3 P4
OSC CARD CONNECTIONS
P1
P13 P10
P7
PY8
PUMP
CONNECTION
POS
LINE
PUMP
TMM
* ACCEL
PUMP TMM
ACCEL SWITCH
TRACTION
STATUS CODE
BDI
INTERRUPT
50
13A
*
FOOT
BRAKE
SWITCH
F2
SP
A2
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
FU3
* SWITCH
3 KEY
BRAKE SWITCH
*
10
SP
POSSIBLE CAUSE
-Open wire connection to Pin 17
- Shorted line Driver transistor
60
* ACCEL
7 15
29
*
FU4
* FU1
TMM7 43
88
+
A1
*
POS A1 F1
A2 CONTROL POWER
CONNECTION
TMM7 89
NEG A2 F2
*
44
START
SWITCH
PUMP
TMM
P18 P17 P2
P5 PY9
P6 P3 P4
OSC CARD CONNECTIONS
P1
P13 P10
P7
PY8
PUMP
CONNECTION
POS
LINE
FWD
REV
10
24
FU5
Defective control.
= Replace controller unit.
BRAKE SWITCH
DIRECT SWITCH
*
*
A1
F1
*
F2
SP
PUMP TMM
ACCEL SWITCH
Circuits valid
for
Traction
Controller
CORRECTIVE
ACTIONS
ARMATURE
NO
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.
FIELD
MEMORY RECALL
STEER PUMP
ARM
-64
DESCRIPTION OF
STATUS
PUMP CONNECTION
BATT NEG
TRACTION
STATUS CODE
50
13A
*
*
FOOT
BRAKE
SWITCH
A2
November 1999
BDI
INTERRUPT
SX TRANSISTOR CONTROL
YES
Circuits valid
for
Traction
Controller
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.
CORRECTIVE
ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
FU3
* SWITCH
3 KEY
BRAKE SWITCH
*
10
SP
POSSIBLE CAUSE
60
FWD
REV
10
24
* ACCEL
START
7 15 SWITCH 6
FU5
LINE
29
*
STEER PUMP
ARM
PUMP CONNECTION
BATT NEG
FU4
* FU1
TMM7 43
88
+
A1
*
POS A1 F1
A2 CONTROL POWER
CONNECTION
TMM7 89
NEG A2 F2
*
44
PUMP
TMM
P18 P17 P2
P5 PY9
P6 P3 P4
OSC CARD CONNECTIONS
P1
P13 P10
P7
PY8
PUMP
CONNECTION
POS
BRAKE SWITCH
DIRECT SWITCH
*
*
A1
F1
*
PUMP TMM
ACCEL SWITCH
MEMORY RECALL
ARMATURE
-65
DESCRIPTION OF
STATUS
FIELD
TRACTION
STATUS CODE
50
BDI
INTERRUPT
13A
*
*
F2
SP
FOOT
BRAKE
SWITCH
A2
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate
=
Line contactor opens
POSSIBLE CAUSE
= Shorted field F1 to F2
= F1 or F2 terminals shorted to
battery positive (B+)
= F1 or F2 terminals shorted to
battery negative (B-)
FU3
* SWITCH
3 KEY
BRAKE SWITCH
*
10
SP
L
60
FWD
REV
10
24
* ACCEL
START
7 15 SWITCH 6
FU5
29
*
FU4
* FU1
TMM7 43
88
+
A1
*
POS A1 F1
A2 CONTROL POWER
CONNECTION
TMM7 89
NEG A2 F2
*
44
PUMP
TMM
P18 P17 P2
P5 PY9
P6 P3 P4
OSC CARD CONNECTIONS
P1
P13 P10
P7
PY8
PUMP
CONNECTION
POS
LINE
BRAKE SWITCH
DIRECT SWITCH
*
*
A1
F1
*
F2
SP
PUMP TMM
ACCEL SWITCH
Circuits valid
for
Traction
Controller
CORRECTIVE
ACTIONS
ARMATURE
YES
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.
FIELD
MEMORY RECALL
STEER PUMP
ARM
-66
DESCRIPTION OF
STATUS
PUMP CONNECTION
BATT NEG
TRACTION
STATUS CODE
50
13A
*
*
FOOT
BRAKE
SWITCH
A2
November 1999
BDI
INTERRUPT
SX TRANSISTOR CONTROL
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
FU3
* SWITCH
3 KEY
BRAKE SWITCH
*
10
SP
POSSIBLE CAUSE
= 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
60
FWD
REV
10
24
* ACCEL
FU5
7 15
29
*
FU4
* FU1
TMM7 43
88
+
A1
*
POS A1 F1
A2 CONTROL POWER
CONNECTION
TMM7 89
NEG A2 F2
*
44
START
SWITCH
PUMP
TMM
P18 P17 P2
P5 PY9
P6 P3 P4
OSC CARD CONNECTIONS
P1
P13 P10
P7
PY8
PUMP
CONNECTION
POS
LINE
BRAKE SWITCH
DIRECT SWITCH
*
*
A1
F1
*
PUMP TMM
ACCEL SWITCH
Circuits valid
for
Traction
Controller
CORRECTIVE
ACTIONS
ARMATURE
YES
FIELD
MEMORY RECALL
STEER PUMP
ARM
-67
DESCRIPTION OF
STATUS
PUMP CONNECTION
BATT NEG
TRACTION
STATUS CODE
50
BDI
INTERRUPT
13A
*
*
F2
SP
FOOT
BRAKE
SWITCH
A2
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Line contactor opens and closes,
then opens and can only close by
opening and closing the key switch.
FU3
* SWITCH
3 KEY
BRAKE SWITCH
*
10
SP
L
60
POSSIBLE CAUSE
= Unplugging the battery connector
during regenerative braking.
= Line contactor bouncing open
during regen.
= Main power fuse opening during
regen.
= Intermittent battery plug
connection.
* Limit Voltage:
Limit
50V
70V
96V
Batt.
36V
48V
72/80V
FWD
REV
10
24
* ACCEL
START
7 15 SWITCH 6
FU5
29
*
FU4
* FU1
TMM7 43
88
+
A1
*
POS A1 F1
A2 CONTROL POWER
CONNECTION
TMM7 89
NEG A2 F2
*
44
PUMP
TMM
P18 P17 P2
P5 PY9
P6 P3 P4
OSC CARD CONNECTIONS
P1
P13 P10
P7
PY8
PUMP
CONNECTION
POS
LINE
BRAKE SWITCH
DIRECT SWITCH
*
*
A1
F1
*
F2
SP
PUMP TMM
ACCEL SWITCH
Circuits valid
for
Traction
Controller
CORRECTIVE
ACTIONS
ARMATURE
YES
FIELD
MEMORY RECALL
STEER PUMP
ARM
-76
DESCRIPTION OF
STATUS
PUMP CONNECTION
BATT NEG
TRACTION
STATUS CODE
50
13A
*
*
FOOT
BRAKE
SWITCH
A2
November 1999
BDI
INTERRUPT
SX TRANSISTOR CONTROL
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Line contactor opens and closes, then
opens and can only close by opening
and closing the key switch.
FU3
* SWITCH
3 KEY
BRAKE SWITCH
*
10
SP
L
60
POSSIBLE CAUSE
Defective control.
= Replace controller unit
FWD
REV
10
24
* ACCEL
FU5
7 15
29
*
FU4
* FU1
TMM7 43
88
+
A1
*
POS A1 F1
A2 CONTROL POWER
CONNECTION
TMM7 89
NEG A2 F2
*
44
START
SWITCH
PUMP
TMM
P18 P17 P2
P5 PY9
P6 P3 P4
OSC CARD CONNECTIONS
P1
P13 P10
P7
PY8
PUMP
CONNECTION
POS
LINE
BRAKE SWITCH
DIRECT SWITCH
*
*
A1
F1
*
F2
SP
PUMP TMM
ACCEL SWITCH
Circuits valid
for
Traction
Controller
CORRECTIVE ACTIONS
ARMATURE
YES
FIELD
MEMORY RECALL
STEER PUMP
ARM
-77
DESCRIPTION OF
STATUS
PUMP CONNECTION
BATT NEG
TRACTION
STATUS CODE
50
13A
*
*
FOOT
BRAKE
SWITCH
A2
November 1999
BDI
INTERRUPT
SX TRANSISTOR CONTROL
TRACTION
STATUS CODE
-90
MEMORY RECALL
YES
Circuits valid
for
Traction
Motor
Temperature
DESCRIPTION OF STATUS
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Status code flashes on and off.
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).
P16
USER SW
NEG
SC90
TRACTION
STATUS CODE
-91
MEMORY RECALL
YES
Circuits valid
for
Traction
Motor
Temperature
DESCRIPTION OF STATUS
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Status code flashes on and off.
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).
P11
USER SW
NEG
SC91
November 1999
SX TRANSISTOR CONTROL
TRACTION
STATUS CODE
-93
MEMORY RECALL
YES
Circuits valid
for
Steer
Pump
Motor
Brush Wear
Indicator
DESCRIPTION OF STATUS
Steering pump motor brush wear
indicator has detected worn brush.
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Status code flashes on and off.
POSSIBLE CAUSE
User defined status code is displayed by motor
brush sensor closure to battery positive.
Plug P3 (pump) is shorted to positive.
Defective input switch (shorted).
P3
USER SW
POS
SC93
TRACTION
STATUS CODE
-93
MEMORY RECALL
YES
Circuits valid
for
Steering
Pump
Motor
Brush Wear
Indicator
DESCRIPTION OF STATUS
Steering pump motor brush wear
indicator has detected worn brush.
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Status code flashes on and off.
POSSIBLE CAUSE
User defined status code is displayed by motor
brush sensor closure to battery positive.
Plug P4 (pump) is shorted to positive.
Defective input switch (shorted).
P4
USER SW
POS
SC93A
November 1999
SX TRANSISTOR CONTROL
TRACTION
STATUS CODE
-94
MEMORY RECALL
YES
Circuits valid
for
Traction
Motor
Brush Wear
Indicator
DESCRIPTION OF STATUS
Traction motor brush wear indicator
has detected worn brush.
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Status code flashes on and off.
POSSIBLE CAUSE
User defined status code is displayed by motor
brush sensor closure to battery positive.
Plug P5 (pump) is shorted to positive.
P5
POS
SC94
TRACTION
STATUS CODE
-94
MEMORY RECALL
YES
Circuits valid
for
Traction
Motor
Brush Wear
DESCRIPTION OF STATUS
Traction motor brush wear indicator
had detected worn brush.
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Status code flashes on and off.
POSSIBLE CAUSE
User defined status code is displayed by motor
brush sensor closure to battery positive.
.
Plug P6 (pump) is shorted to positive.
P6
POS
SC94A
November 1999
SX TRANSISTOR CONTROL
TRACTION
STATUS CODE
-95
MEMORY RECALL
YES
Circuits valid
for
Pump
Motor
Brush Wear
Indicator
DESCRIPTION OF STATUS
Pump motor brush wear indicator has
detected worn brush.
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Status code flashes on and off.
POSSIBLE CAUSE
User defined status code is displayed by motor
brush sensor closure to battery positive.
Plug P8 (pump) is shorted to positive.
P8
POS
SC95
TRACTION
STATUS CODE
-95
MEMORY RECALL
YES
Circuits valid
for
Pump
Motor
Brush Wear
Indicator
DESCRIPTION OF STATUS
Pump motor brush wear indicator has
detected worn brush.
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Status code flashes on and off.
POSSIBLE CAUSE
User defined status code is displayed by motor
brush sensor closure to battery positive.
Plug P9 (pump) is shorted to positive.
P9
POS
SC95A
November 1999
SX TRANSISTOR CONTROL
TRACTION
STATUS CODE
-99
MEMORY RECALL
YES
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS
Maintenance alert and speed limit.
CORRECTIVE ACTIONS
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.
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.
TROUBLE-SHOOTING DIAGRAM
NO DIAGRAM
November 1999
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
Circuits valid
for
Pump
Controller
CORRECTIVE ACTIONS
13C
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
SPEED 2 switch is closed or shorted to battery
negative.
=
Verify connections at P19 and Battery
negative. Replace switch, if necessary.
7
12
19
20
21
BATT
NEG
52
53
51
13C
ACCELERATOR
SWITCH
NO
SPEED 1
MEMORY RECALL
SPEED 4
-102
DESCRIPTION OF STATUS
SX-2
CONTROL
PLUG PL2
PUMP
STATUS CODE
51
ACCELERATOR
SWITCH
BATT
NEG
52
53
SPEED 1
7
12
19
20
21
SPEED 2
POSSIBLE CAUSE
SPEED 1 switch is closed or shorted to battery
negative.
=
Verify connections at P12 and Battery
negative. Replace switch, if necessary.
SPEED 4
Circuits valid
for
Pump
Controller
CORRECTIVE ACTIONS
SPEED 2
NO
SPEED 3
MEMORY RECALL
SPEED 3
-101
DESCRIPTION OF STATUS
SX-2
CONTROL
PLUG PL2
PUMP
STATUS CODE
November 1999
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
Circuits valid
for
Pump
Controller
CORRECTIVE ACTIONS
13C
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
SPEED 4 switch is closed or shorted to battery
negative.
=
Verify connections at P21 and Battery
negative. Replace switch, if necessary.
7
12
19
20
21
BATT
NEG
52
53
51
13C
ACCELERATOR
SWITCH
NO
SPEED 1
MEMORY RECALL
SPEED 4
-104
DESCRIPTION OF STATUS
SX-2
CONTROL
PLUG PL2
PUMP
STATUS CODE
51
ACCELERATOR
SWITCH
BATT
NEG
52
53
SPEED 1
7
12
19
20
21
SPEED 2
POSSIBLE CAUSE
SPEED 3 switch is closed or shorted to battery
negative.
=
Verify connections at P20 and Battery
negative. Replace switch, if necessary.
SPEED 4
Circuits valid
for
Pump
Controller
CORRECTIVE ACTIONS
SPEED 2
NO
SPEED 3
MEMORY RECALL
SPEED 3
-103
DESCRIPTION OF STATUS
SX-2
CONTROL
PLUG PL2
PUMP
STATUS CODE
November 1999
PUMP
STATUS CODE
-117
MEMORY RECALL
NO
Circuits valid
for
Pump
Controller
DESCRIPTION OF STATUS
Card Type selection is invalid.
CORRECTIVE ACTIONS
SYMPTOM
Control will not operate.
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.
TROUBLE-SHOOTING DIAGRAM
NO
GRAPHIC
FOR THIS
STATUS CODE
-127
MEMORY RECALL
YES
Circuits valid
for
Pump
Controller
DESCRIPTION OF STATUS
Control logic card power supply is less
than 10 VDC.
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
FU3
SYMPTOM
Control will not operate.
KEY SWITCH
FU2
POSSIBLE CAUSE
Discharged Battery
=Check battery to insure proper state of
charge.
LINE FU1
P1 P2
POS
A1
POWER CONNECTIONS
NEG
A2
ARMATURE FIELD
PUMP
STATUS CODE
November 1999
PUMP
STATUS CODE
-128
MEMORY RECALL
YES
Circuits valid
for
Pump
Controller
DESCRIPTION OF STATUS
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
KEY SWITCH
FU3
SYMPTOM
Control will not operate.
FU2
POSSIBLE CAUSE
Continued operation of vehicle in high
motor current condition.
LINE FU1
P1 P2
POS
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
FU2
1
STATUS CODE 93 INPUT
STATUS CODE 93 INPUT
STATUS CODE 94 INPUT
STATUS CODE 94 INPUT
STATUS CODE 95 INPUT
STATUS CODE 95 INPUT
STATUS CODE 92 INPUT
STATUS CODE 90 INPUT
STATUS CODE 91 INPUT
BRUSH WEAR OUTPUT
OVER TEMP OUTPUT
3
4
5
6
8
9
15
16
11
13
14
A1
P
A1
PUMP CONTROL
POWER
CONNECTION
A2
A2
A1
A2
TO
TRACTION
PL2-10
51
12
52
19
53
20
21
ACCELERATOR
SWITCH
P
5A
50
10
SPEED 1
12-1
SPEED 2
10
FU6
SPEED 3
POSSIBLE CAUSE
KEY SW.
SPEED 4
SYMPTOM
Reduced or no power to pump motor in
control range.
SX-2
CONTROL PLUG PL2
Circuits valid
for
Pump
Controller
FIELD ARMATURE
NO
LINE
CONTACTOR
MEMORY RECALL
A2
DESCRIPTION OF
STATUS
BATT (-)
-141
A1
POWER CONNECTIONS
NEG
PUMP
STATUS CODE
ARMATURE FIELD
13C
November 1999
3
4
5
6
8
9
15
16
11
13
14
A1
A1
PUMP CONTROL
POWER
CONNECTION
N
BATT (-)
*
*
13C
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
SYMPTOM
No power to pump motor in control range.
POSSIBLE CAUSE
Control is defective.
=Replace controller unit.
21
KEY SW.
10
FU6
12-1
FU2
5A
1
STATUS CODE 93 INPUT
STATUS CODE 93 INPUT
STATUS CODE 94 INPUT
STATUS CODE 94 INPUT
STATUS CODE 95 INPUT
STATUS CODE 95 INPUT
STATUS CODE 92 INPUT
STATUS CODE 90 INPUT
STATUS CODE 91 INPUT
BRUSH WEAR OUTPUT
OVER TEMP OUTPUT
3
4
5
6
8
9
15
16
11
13
14
A1
P
A1
PUMP CONTROL
POWER
CONNECTION
A2
A2
A1
A2
50
10
TO
TRACTION
PL2-10
51
12
52
19
53
20
21
ACCELERATOR
SWITCH
Circuits valid
for
Pump
Controller
53
20
SPEED 2
NO
52
19
SPEED 1
MEMORY RECALL
A2
51
LINE
CONTACTOR
-143
A2
A2
DESCRIPTION OF
STATUS
BATT (-)
PUMP
STATUS CODE
A1
7
12
ACCELERATOR
SWITCH
1
STATUS CODE 93 INPUT
STATUS CODE 93 INPUT
STATUS CODE 94 INPUT
STATUS CODE 94 INPUT
STATUS CODE 95 INPUT
STATUS CODE 95 INPUT
STATUS CODE 92 INPUT
STATUS CODE 90 INPUT
STATUS CODE 91 INPUT
BRUSH WEAR OUTPUT
OVER TEMP OUTPUT
TO
TRACTION
PL2-10
SPEED 2
5A
50
10
SPEED 1
12-1
SPEED 3
FU6
FU2
SPEED 4
10
SPEED 3
POSSIBLE CAUSE
Control is defective.
= Replace controller unit.
KEY SW.
SPEED 4
SYMPTOM
No power to pump motor in control
range.
TROUBLE-SHOOTING DIAGRAM
SX-2
CONTROL PLUG PL2
Circuits valid
for
Pump
Controller
CORRECTIVE ACTIONS
FIELD ARMATURE
NO
SX-2
CONTROL PLUG PL2
MEMORY RECALL
FIELD ARMATURE
-142
DESCRIPTION OF
STATUS
LINE
CONTACTOR
PUMP
STATUS CODE
13C
November 1999
1
STATUS CODE 93 INPUT
STATUS CODE 93 INPUT
STATUS CODE 94 INPUT
STATUS CODE 94 INPUT
STATUS CODE 95 INPUT
STATUS CODE 95 INPUT
STATUS CODE 92 INPUT
STATUS CODE 90 INPUT
STATUS CODE 91 INPUT
BRUSH WEAR OUTPUT
OVER TEMP OUTPUT
3
4
5
6
8
9
15
16
11
13
14
A1
A1
PUMP CONTROL
POWER
CONNECTION
*
*
13C
TROUBLE-SHOOTING DIAGRAM
KEY SW.
10
FU6
12-1
FU2
P
5A
1
STATUS CODE 93 INPUT
STATUS CODE 93 INPUT
STATUS CODE 94 INPUT
STATUS CODE 94 INPUT
STATUS CODE 95 INPUT
STATUS CODE 95 INPUT
STATUS CODE 92 INPUT
STATUS CODE 90 INPUT
STATUS CODE 91 INPUT
BRUSH WEAR OUTPUT
OVER TEMP OUTPUT
3
4
5
6
8
9
15
16
11
13
14
A1
A1
PUMP CONTROL
POWER
CONNECTION
A2
A2
A1
A2
50
10
TO
TRACTION
PL2-10
51
12
52
19
53
20
21
ACCELERATOR
SWITCH
POSSIBLE CAUSE
Control is defective.
= Replace controller unit.
CORRECTIVE ACTIONS
SYMPTOM
With no pump contactor, the control may
run continuously.
SPEED 1
Circuits valid
for
Pump
Controller
53
20
SPEED 2
YES
A2
52
19
21
A2
BATT (-)
MEMORY RECALL
A2
51
LINE
CONTACTOR
-145
DESCRIPTION OF STATUS
BATT (-)
PUMP
STATUS CODE
A1
7
12
SPEED 4
5A
TO
TRACTION
PL2-10
50
10
ACCELERATOR
SWITCH
SPEED 1
12-1
SPEED 2
FU6
FU2
SPEED 3
10
SPEED 3
POSSIBLE CAUSE
Control is defective.
= Replace controller unit.
KEY SW.
SPEED 4
SYMPTOM
With no pump contactor, control may run
continuously.
TROUBLE-SHOOTING DIAGRAM
SX-2
CONTROL PLUG PL2
Circuits valid
for
Pump
Controller
CORRECTIVE ACTIONS
FIELD ARMATURE
YES
SX-2
CONTROL PLUG PL2
MEMORY RECALL
FIELD ARMATURE
-144
DESCRIPTION OF STATUS
LINE
CONTACTOR
PUMP
STATUS CODE
13C
November 1999
TROUBLE-SHOOTING DIAGRAM
5A
1
STATUS CODE 93 INPUT
STATUS CODE 93 INPUT
STATUS CODE 94 INPUT
STATUS CODE 94 INPUT
STATUS CODE 95 INPUT
STATUS CODE 95 INPUT
STATUS CODE 92 INPUT
STATUS CODE 90 INPUT
STATUS CODE 91 INPUT
BRUSH WEAR OUTPUT
OVER TEMP OUTPUT
Control is defective.
= Replace controller unit.
3
4
5
6
8
9
15
16
11
13
14
A1
A1
PUMP CONTROL
POWER
CONNECTION
*
*
13C
TROUBLE-SHOOTING DIAGRAM
10
FU6
12-1
FU2
P
5A
1
STATUS CODE 93 INPUT
STATUS CODE 93 INPUT
STATUS CODE 94 INPUT
STATUS CODE 94 INPUT
STATUS CODE 95 INPUT
STATUS CODE 95 INPUT
STATUS CODE 92 INPUT
STATUS CODE 90 INPUT
STATUS CODE 91 INPUT
BRUSH WEAR OUTPUT
OVER TEMP OUTPUT
3
4
5
6
8
9
15
16
11
13
14
A1
P
A1
PUMP CONTROL
POWER
CONNECTION
A2
A2
A1
A2
50
10
TO
TRACTION
PL2-10
51
12
52
19
53
20
21
ACCELERATOR
SWITCH
KEY SW.
SPEED 1
SYMPTOM
Pump control will not operate.
CORRECTIVE ACTIONS
POSSIBLE CAUSE
Defective line contactor.
= Check for open line contactor
power tips.
53
20
SPEED 2
Circuits valid
for
Pump
Controller
52
19
SPEED 3
YES
A2
51
21
A2
BATT (-)
MEMORY RECALL
A2
7
12
LINE
CONTACTOR
-150
DESCRIPTION OF
STATUS
BATT (-)
PUMP STATUS
CODE
A1
TO
TRACTION
PL2-10
50
10
ACCELERATOR
SWITCH
SPEED 1
12-1
SPEED 2
FU6
FU2
SPEED 3
10
SPEED 4
POSSIBLE CAUSE
Check for short circuit from the motor
armature to the frame of the vehicle.
KEY SW.
SPEED 4
SYMPTOM
Pump control will not operate.
SX-2
CONTROL PLUG PL2
Circuits valid
for
Pump
Controller
CORRECTIVE ACTIONS
FIELD ARMATURE
YES
SX-2
CONTROL PLUG PL2
MEMORY RECALL
FIELD ARMATURE
-146
DESCRIPTION OF STATUS
LINE
CONTACTOR
PUMP
STATUS CODE
13C
November 1999
TROUBLE-SHOOTING DIAGRAM
FU2
1
STATUS CODE 93 INPUT
STATUS CODE 93 INPUT
STATUS CODE 94 INPUT
STATUS CODE 94 INPUT
STATUS CODE 95 INPUT
STATUS CODE 95 INPUT
STATUS CODE 92 INPUT
STATUS CODE 90 INPUT
STATUS CODE 91 INPUT
BRUSH WEAR OUTPUT
OVER TEMP OUTPUT
Defective control.
= Replace controller unit.
Note: Repeated 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.
A1
A1
PUMP CONTROL
POWER
CONNECTION
N
BATT (-)
*
*
13C
TROUBLE-SHOOTING DIAGRAM
KEY SW.
10
FU6
12-1
FU2
5A
1
STATUS CODE 93 INPUT
STATUS CODE 93 INPUT
STATUS CODE 94 INPUT
STATUS CODE 94 INPUT
STATUS CODE 95 INPUT
STATUS CODE 95 INPUT
STATUS CODE 92 INPUT
STATUS CODE 90 INPUT
STATUS CODE 91 INPUT
BRUSH WEAR OUTPUT
OVER TEMP OUTPUT
3
4
5
6
8
9
15
16
11
13
14
A1
A1
PUMP CONTROL
POWER
CONNECTION
A2
A2
A1
A2
50
10
TO
TRACTION
PL2-10
51
12
52
19
53
20
21
ACCELERATOR
SWITCH
POSSIBLE CAUSE
Control is defective.
=Replace controller unit.
CORRECTIVE ACTIONS
SYMPTOM
Pump control will not operate.
SPEED 1
Circuits valid
for
Pump
Controller
53
20
SPEED 2
NO
A2
52
19
SPEED 3
MEMORY RECALL
A2
51
LINE
CONTACTOR
-157
A1
7
12
21
A2
DESCRIPTION OF
STATUS
BATT (-)
PUMP
STATUS CODE
3
4
5
6
8
9
15
16
11
13
14
ACCELERATOR
SWITCH
P
5A
TO
TRACTION
PL2-10
50
10
SPEED 2
12-1
SPEED 1
10
FU6
SPEED 4
POSSIBLE CAUSE
Defective control fuse.
= Check control fuse for open circuit,
replace fuse, if necessary.
KEY SW.
SPEED 4
SYMPTOM
Pump control will not operate.
SPEED 3
CORRECTIVE ACTIONS
SX-2
CONTROL PLUG PL2
Circuits valid
for
Pump
Controller
FIELD ARMATURE
NO
SX-2
CONTROL PLUG PL2
MEMORY RECALL
FIELD ARMATURE
-151
DESCRIPTION OF STATUS
LINE
CONTACTOR
PUMP STATUS
CODE
13C
November 1999
TROUBLE-SHOOTING DIAGRAM
P
5A
1
STATUS CODE 93 INPUT
STATUS CODE 93 INPUT
STATUS CODE 94 INPUT
STATUS CODE 94 INPUT
STATUS CODE 95 INPUT
STATUS CODE 95 INPUT
STATUS CODE 92 INPUT
STATUS CODE 90 INPUT
STATUS CODE 91 INPUT
BRUSH WEAR OUTPUT
OVER TEMP OUTPUT
A1
A1
PUMP CONTROL
POWER
CONNECTION
53
20
21
*
*
13C
TROUBLE-SHOOTING DIAGRAM
KEY SW.
10
FU6
12-1
FU2
P
5A
1
STATUS CODE 93 INPUT
STATUS CODE 93 INPUT
STATUS CODE 94 INPUT
STATUS CODE 94 INPUT
STATUS CODE 95 INPUT
STATUS CODE 95 INPUT
STATUS CODE 92 INPUT
STATUS CODE 90 INPUT
STATUS CODE 91 INPUT
BRUSH WEAR OUTPUT
OVER TEMP OUTPUT
3
4
5
6
8
9
15
16
11
13
14
A1
P
A1
PUMP CONTROL
POWER
CONNECTION
A2
A2
A1
A2
50
10
TO
TRACTION
PL2-10
51
12
52
19
53
20
21
ACCELERATOR
SWITCH
SYMPTOM
Pump control will not operate.
SPEED 2
CORRECTIVE ACTIONS
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.
52
19
SPEED 1
Circuits valid
for
Pump
Controller
51
SPEED 3
NO
A2
A2
BATT (-)
MEMORY RECALL
A2
7
12
LINE
CONTACTOR
-181
A1
TO
TRACTION
PL2-10
DESCRIPTION OF
STATUS
BATT (-)
PUMP
STATUS CODE
3
4
5
6
8
9
15
16
11
13
14
50
10
ACCELERATOR
SWITCH
12-1
SPEED 2
FU6
FU2
SPEED 1
10
SPEED 4
POSSIBLE CAUSE
(Line contactor controlled by traction
control).
Line Contactor opened up during run.
= Check connection from P17 to Line
coil (-) for loose connection.
= Check connection from battery (+) to
Line coil (+) for loose connection.
= Check power connection from battery
(+) to contactor L.
= Check for blown fuse at pump control.
= Check for dirty contactor tips.
KEY SW.
SPEED 3
SYMPTOM
Pump control will not operate.
SPEED 4
CORRECTIVE ACTIONS
SX-2
CONTROL PLUG PL2
Circuits valid
for
Pump
Controller
FIELD ARMATURE
NO
SX-2
CONTROL PLUG PL2
MEMORY RECALL
FIELD ARMATURE
-180
DESCRIPTION OF STATUS
LINE
CONTACTOR
PUMP
STATUS CODE
13C
November 1999
SX TRANSISTOR CONTROL
TMM7A
Pump
Card
Control
Status
Terminal
Code
Connect To
Terminal
TB1
P16
90 *
Neg
TB3
P11
91
Neg
TB4
P15
92
Neg
TB5
P3
93 *
Pos
TB6
P4
93 *
Pos
TB8
P5
94
Pos
TB10
P6
94
Pos
TB11
P8
95
Pos
TB12
P9
95
Pos
* 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.
10
10
11
12
13
A3-2
BATTERY
NEGATIVE
A3-1
A2-2
14
A2-1
A1-2
A1-1
10
11
12
15
BATTERY
POSITIVE
7
3
14
10
11
12
ARM
2
1
ARM
2
2
ARM
2
3
TRACTION
PUMP
13
PWR STEER
November 1999
15
SX TRANSISTOR CONTROL
PZ
10
PZ
11
A3-2
PA
4
A3-1
PA
2
A2-2
PA
1
A2-1
PB
6
A1-2
1
BATTERY
NEGATIVE
PA
6
A1-1
PA
3
10
11
12
PY
10
PA
3
PA
1
PA
2
PA
4
PA
5
PZ
10
PZ
11
BATTERY
POSITIVE
TO PY10
TRACTION
ARM
2
1
ARM
2
2
TRACTION
PUMP
ARM
2
3
PWR STEER
7
4
5
6
8
10
14
11
12
13
15
3.36
(85.3)
5.8
(147
.2
6.15 0)
156.
20
1.60
(40.6)
.8
(20.3)
November 1999
ADJUSTABLE FEATURES
Page 52
SX TRANSISTOR CONTROLS
Key Switch On
Verify Each LED Segment
8888
If Maintenance Code
Is Active
If Maintenance Code
Is Not Active
BDI Display or
Blank Display
(no BDI used)
Diagnostics Override
With Fault
Run Mode
BDI Display or
Blank Display
(no BDI used)
Diagnostics Override
With Fault
Key Switch
Off
ADJUSTABLE FEATURES
Page 53
SX TRANSISTOR CONTROLS
SET-UP MODE
DISPLAY
SHOWS
REMARKS
8888
Segment Check
Displayed
U005
085
Push CONT
085
Display Value
Will Blink
Displays Battery
State-Of-Charge When
Fault Occurred
125
Value Changes
While Blinking
Push STORE
125
Push ESC
8888
Segment Check
Displayed
ACTION
November 1999
ADJUSTABLE FEATURES
Page 54
SX TRANSISTOR CONTROLS
FUNCTION 3
LX g
ARMATURE CONTROLLED
ACCELERATION
(Push 3)
HANDSET
EVC
CONT
STORE
10
11
12
13
14
15
ESC
FUNCTION 4
NOT APPLICABLE
CREEP SPEED
( Push 2 )
Max
Set
55
455
0 to 255
Resolution Per
Unit Value
1.57 amps
Example If
Set at 20
86.4 amps
NOT APPLICABLE
ADJUSTABLE FEATURES
Page 55
SX TRANSISTOR CONTROLS
Volts
48
72/80
Min
0
0
Max
60
55
Set
51 to 255
51 to 255
Resolution
Per unit value
.314
.269
Min
0
0
Max
60
55
Set
51 to 255
51 to 255
Resolution
Per unit value
.314
.269
Volts
48
72/80
Min
0
0
FUNCTION 11
Min
183A
Max
597A
Set
0 to 255
72/80
26A
440A
0 to 255
Resolution
Per unit value
(1.625 x
setting) + 183
1.625 x setting
Example
If set at 20
215 amp
58 amps
Resolution
Per unit value
.314
.269 amps
Example
If set at 71
6.28A
5.38A
MAX ARMATURE % ON
(Push 4)
Set
51 to 255
51 to 255
FUNCTION 9
Max
60
55
FUNCTION 12
NOT APPLICABLE
SPEED LIMIT 3
( Push 13 )
INTERNAL RESISTANCE
COMPENSATION
( Push 14 )
November 1999
ADJUSTABLE FEATURES
Page 56
SX TRANSISTOR CONTROLS
VDrop
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
Setting
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
VDrop
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
BATTERY VOLTS
(Push l5)
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
FUNCTION 16
NOT APPLICABLE
This function allows for the selection of the card type used
for your vehicle's application. This function should be set at
a value of 57
Warning: These settings must be changed by authorized
personnel only, following instructions supplied by the
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 misoperation or damage to the control and/or motors.
FUNCTION 18
Range
Setting
Resolution
1.5 to 65 seconds
Between 0 and 128
0.5 seconds per set unit
Range
Setting
Resolution
0.5 to 63 seconds
Between 129 and 255
0.5 seconds per set unit
ADJUSTABLE FEATURES
Page 57
SX TRANSISTOR CONTROLS
Range
Set
Example
FUNCTION 20
0 to 99
0 to 99
9999 Hours
MAINTENANCE CODE THOUSANDS
AND HUNDREDS HOURS SET
( Push CONT 5 )
FNT 21-51
VAL
[ (
FUNCTION 24
[(
6.50
MONITOR
( Push CONT 10)
RATIO
( Push CONT 11)
Volts
48
Max Change
.48
Set
0 to 40
Resolution
.012
0 to 240
0 to 240
9999 Hours
FUNCTION 48
November 1999
ADJUSTABLE FEATURES
Page 58
SX TRANSISTOR CONTROLS
Range
Set
Resolution
Example
FUNCTION 52
Range
Setting
Resolution
FUNCTION 53
0 to 414 Amps
0 to 255
1.625 per set unit
Min
0
0
Max
60
55
Set
51 to 255
51 to 255
FUNCTION 50
Resolution
Per unit value
.314
.269
FUNCTION 54
MODE 3 ARMATURE
CONTROLLED ACCELERATION
( Push CONT 9)
ADJUSTABLE FEATURES
SX TRANSISTOR CONTROLS
Page 59
MODE 4 ARMATURE
CONTROLLED ACCELERATION
( Push CONT 13)
November 1999
ADJUSTABLE FEATURES
Page 60
SX TRANSISTOR CONTROLS
MAXIMUM
FIELD CURRENT
ZERO
MAXIMUM
ZERO
ARMATURE CURRENT
The "full load transition point"
is calculated by the control. This
function sets the maximum field
current transition point at
approximately 80% of the
maximum armature current.
The " maximum armature
current" setting is adjusted by
Function 4. The function along
with the "maximum field
current" (Function 8) sets the
maximum torque of the motor.
November 1999
ADJUSTABLE FEATURES
Page 61
NOT APPLICABLE
INTERNAL RESISTANCE
COMPENSATION START
(Push 2)
0 to 1325 amps
52 to 255
6.5 amps per set unit
CONTROLLED ACCELERATION
(Push 3)
CURRENT LIMIT
(Push 4)
INTERNAL RESISTANCE
COMPENSATION RATE
(Push 7)
NOT APPLICABLE
ADJUSTABLE FEATURES
TRANSISTOR PUMP CONTROLS
Page 62
SETTING
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
FUNCTION 17:
SPEED / TORQUE
COMPENSATION TABLE
VOLTAGE
DROP
SETTING
11.44
17
7.60
18
5.72
19
4.57
20
3.81
21
3.27
22
2.86
23
2.54
24
2.28
25
2.08
26
1.90
27
1.76
28
1.63
29
1.52
30
1.43
31
VOLTAGE
DROP
1.34
1.27
1.20
1.14
1.09
1.04
0.99
0.95
0.91
0.88
0.85
0.82
0.79
0.76
0.74
Function
High C/L
BDI Lockout
Without Pump
Ctr/PMT
63 to 71
FUNCTION 49:
ADJUSTABLE FEATURES
TRANSISTOR PUMP CONTROLS
switch input signal is received by the control card. SL4
limit switch is a normally open switch connected to battery
negative, the switch closing enables speed limit.
Range
Setting
Resolution
Page 63
(Push CONT 13)
Same as Function 48.
FUNCTION 61:
FUNCTION 51
FUNCTION 62:
NOT APPLICABLE
NOT APPLICABLE
NOT APPLICABLE
Page 64
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.
GE Electric Vehicle
Motors & Controls
Part Number
IC3645LXTDD
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.
BATTERY
T=Traction Only
P=Traction & Pump
3=Round Face with four
display symbols
For Custom Dash Displays,
contact your vehicleOEM.
EVT100ZX
PUSH
PUSH
Reference
AMP#102241-3
AMP#1-87195-8
44A723596-G09
AMP#175965-2
AMP#175180-1
November1999
Page 65
GE Electric Vehicle
Motors & Controls
Key Switch On
Verify Each LED Segment
8888
0.41
(10.4)
If Maintenance Code
Is Not Active
BDI Display or
Blank Display
(no BDI used)
3.20 (81.3)
2.45 (62.2)
CONNECTOR OMITTED
IF NOT REQUIRED
0.19
(4.8)
Diagnostics Override
With Fault
PUMP
2.00 (50.8)
If Maintenance Code
Is Active
TRACTION
PY3
PY4
PY2
PY1
Run Mode
PUMP
BDI Display or
Blank Display
(no BDI used)
Diagnostics Override
With Fault
Key Switch
Off
PY3
PY4
PY2
PY1
PY5
November1999
Page 66
Func No.
0
1
2
3
4
5
6
7
8
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
1
2
3
4
5
6
7
8
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
HS
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
(18)
(20)
(22)
Traction Control
Function
Not applicable
Creep
Controlled Acceleration
Armature Current Limit
Plug Current Limit
Not applicable
Minimum Field Current
Maximum Field Current
Regen Current Limit
Field Current for Regen
Max Armature % On
Not applicable
Speed Limit 3
IR Compensation
Battery Volts Select
Not applicable
Card Type Select
Steer Pump Time Delay
Maintenance Code HM (Tens/Units)
Maintenance Code HM (Thou/Hun)
Auto Regen
Not applicable
Not applicable
FW Start
Monitor
Ratio
Not applicable
Fault Count Pointer
Not applicable
Not applicable
Aux HM (Tens/Ones)
Aux HM (Thou/Hun)
Stored Status Code #1
BDI 1
Hours (Tens/Ones) 1
Hours (Thou/Hun) 1
Stored Status Code #2
BDI 2
Hours (Tens/Ones) 2
Hours (Thou/Hun) 2
Stored Status Code #3
BDI 3
Hours (Tens/Ones) 3
Access By
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
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
Restrictions
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
For DD on power up
None
None
GE Temporary Storage
GE Temporary Storage
GE Temporary Storage
None
None
None
None
None
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
November 1999
Func No.
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
HS
No.
(26)
(28)
(30)
(32)
(34)
(36)
(38)
(40)
.
(42)
(44)
(46)
Traction Control
Function
Hours (Thou/Hun) 3
BDI 4
Hours (Tens/Ones) 4
Hours (Thou/Hun) 4
Stored Status Code #5
BDI 5
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
Hours(Tens/Ones) 13
Hours(Thou/Hun) 13
Stored Status Code # 14
BDI 14
Hours(Tens/Ones) 14
Hours(Thou/Hun) 14
Stored Status Code # 15
BDI 15
Hours (Tens/Ones) 15
Page 67
Access By
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
Restrictions
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
Reset to Zero Only
November 1999
Func No.
HS
No.
Traction Control
Function
91
Hours (Tens/Ones) 15
92
Hours (Thou/Hun) 15
93
(48) Stored Status Code #16
95
Hours (Tens/Ones) 16
96
Hours (Thou/Hun) 16
67
48
Dash Display CA-1
98
49
Dash Display FWS-1
99
50
Dash Display Ratio2-1
100
51
Dash Display Speed Limit 2 - 1
101
52
Dash Display CA-2
102
53
Dash Display FWS-2
103
54
Dash Display Ratio2-2
104
55
Dash Display Speed Limit 2 - 2
105
56
Dash Display CA-3
106
57
Dash Display FWS-3
107
58
Dash Display Ratio2-3
108
59
Dash Display Speed Limit 2 - 3
109
60
Dash Display CA-4
110
61
Dash Display FWS-4
111
62
Dash Display Ratio2-4
112
63
Dash Display Speed Limit 2 - 4
113
Secure HM (Tens/Ones)
114
Secure HM (Thou/Hun)
115
Secure Aux HM (Tens/Ones)
116
Secure Aux HM (Thou/Hun)
117
Reserved
118
Reserved
119
Reserved
120
Reserved
121
OEM Use
122
OEM Use
123
OEM Use
124
OEM Use
125
OEM Use
126
OEM Use
127
OEM Use
128
OEM Use
Numbers in (bold italics) are Stored Status Code pointers.
Page 68
Access By
Restrictions
PC Only
PC Only
PC Only
PC Only
PC Only
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
None
None
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
None
None
None
None
None
None
None
November 1999