GE Musical Instrument IC3645SP4U400N3 User Manual

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 todays 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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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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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 Donts 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 customers 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.  
January 2000  
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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.  
January 2000  
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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
January 2000  
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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
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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  
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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  
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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  
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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.  
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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  
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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.  
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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  
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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  
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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  
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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)  
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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.  
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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.  
YPlug  
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  
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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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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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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 “YPlug  
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.  
January 2001  
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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  
January 2000  
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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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