GE IC3645SP4U400N3, IC3645SR4U404N2 operation manual Description

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DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL

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	TRACTION	DESCRIPTION OF
	STATUS CODE	STATUS
	-65	The line coil current is too high
	-65	during the run mode
	MEMORY RECALL	CORRECTIVE ACTIONS
	YES	CORRECTIVE ACTIONS
	YES
		SYMPTOM
	Circuits valid	Control will not operate.
	Circuits valid
	for	POSSIBLE CAUSE
	Traction	- Shorted line contactor coil
	Controller	- Short between wires connected to
		line coil (wires #10 and 24)
		If line coil resistance is correct:
		Defective control.
		• Replace controller unit.

CAUSE OF STATUS INDICATION

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.

TROUBLE-SHOOTING DIAGRAM

				BRAKE SW.
FU5	P2 KEY SWITCH P1			SEATSW.	STARTSW.	FOR.SW.	REV. SW.
FU7			SP	SEATSW.	STARTSW.	FOR.SW.	REV. SW.
	TO	P5
	TO		L
FU6	ACCESSORIES	P4
FU6	P3	P4
	PY7					P4
	PY12 P18		P17 P1 P2	P6	P3	P4	P5
	PY10		OSCILLATOR CARD		P7	P10 P9 P12 P8
	PY11		LEFT CONTROL
LINE FU1
							STEER
FU2							ANGLE
FU2					ACC POT		POT
					ACC POT

+	FU4								BDI INTERRUPT
+	FU4
	P
		POS	A1	F1	FIELD	ARMATURE	NEG	A2	F2	FIELD	ARMATURE
-			POWER		FIELD	ARMATURE	NEG	A2	F2	FIELD	ARMATURE
-			POWER				POS	A1	F1
	SP	CONNECTIONS					POWER
		LEFT CONTROL					CONNECTIONS
		NEG	A2	F2			RIGHT CONTROL
P	SP

	TRACTION		DESCRIPTION OF
	STATUS CODE		STATUS
	-66	The field current exceeds the
	-66	current limit of the field transistor.
	MEMORY RECALL	CORRECTIVE ACTIONS
	YES	CORRECTIVE ACTIONS
	YES
		SYMPTOM
	Circuits valid	Control will not operate
	Circuits valid	•	Line contactor opens
	for	POSSIBLE CAUSE
	Traction	•	Shorted field F1 to F2
	Traction	• F1 or F2 terminals shorted to battery
	Controller		positive (B+)
		•	F1 or F2 terminals shorted to battery
			negative (B-)

CAUSE OF STATUS INDICATION

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.

TROUBLE-SHOOTING DIAGRAM

				BRAKE SW.
FU5	P2 KEY SWITCH P1			SEATSW.	STARTSW.	FOR.SW.	REV. SW.
FU7			SP	SEATSW.	STARTSW.	FOR.SW.	REV. SW.
	TO	P5
	TO		L
FU6	ACCESSORIES	P4
FU6	P3	P4
	PY7					P4
	PY12 P18		P17 P1 P2	P6	P3	P4	P5
	PY10		OSCILLATOR CARD		P7	P10 P9 P12 P8
	PY11		LEFT CONTROL
LINE FU1
							STEER
FU2							ANGLE
FU2					ACC POT		POT
					ACC POT

+	FU4								BDI INTERRUPT
+	FU4
	P
		POS	A1	F1	FIELD	ARMATURE	NEG	A2	F2	FIELD	ARMATURE
-			POWER		FIELD	ARMATURE	NEG	A2	F2	FIELD	ARMATURE
-			POWER				POS	A1	F1
	SP	CONNECTIONS					POWER
		LEFT CONTROL					CONNECTIONS
		NEG	A2	F2			RIGHT CONTROL
P	SP

January 2000

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Contents Installation and Operation Table of Contents 20-40 41-4546-52 57-62Basic Operation and Features Motor CharacteristicsMore Features with Fewer Components Solid-State ReversingFlexible System Application Slows with the increase of current in the field1.b Creep Speed 1.c Control Acceleration2 Current Limit 3.c Pedal Position Plug Braking6 Steer Pump Contactor Time Delay 4.b Speed Limits4.c Proportional Operation for Dual Motor Vehicles 5 Ramp Operation 5a Ramp StartDiagnostics 1 Systems Diagnostics 7 On-Board Coil Drivers & Internal Coil SuppressionSystem Protective Override 1 Static Return to Off SRO 2 Accelerator Volts Hold Off3.a Maintenance Alert & Speed Limit 4 Battery Discharge Indication BDI3 Hourmeter Readings 4.a Internal Resistance CompensationBasic Operation and Features Outline DRAWINGS, Elementary Drawings and INPUTS/OUTPUTS Part NumberArgument Outline SX-3 and SR-3 Package Size Drawings and INPUTS/OUTPUTS DRAWINGS, Elementary Drawings and INPUTS/OUTPUTS Control SectionConnections to Main Plug 23 PIN and Y Plug 12 PIN PINDiagnostic Status Codes High-Level Signals Level H Medium-Power Signals Level MP2.d. High Power Signals Level HP Cable Spacing GuidelinesCleaner Reconnect plugs328A1777G1 General Troubleshooting Instructions No seat switch or deadman switch Traction Control CodesTraction Status CodeReverse directional switch is closed on Description of Status Cause of Status IndicationStart switch fails to close Accelerator depressed with noDirection selected KEY Negative Directional switches are closed at Both the forward and reverseSame time Start switch closed on power up after Initial key switch closureDischarged battery Motor field current is high on start up Reverse directionForward direction Volts DC Power supply is less than 10 volts Run modeMotor field current is too high during Traction Controller Slave/auxiliary control Transistor over temperature Open thermal protector TP orMotor armature offset voltage is too LowArmature transistor did not turn off ProperlyThan 12% of battery volts Armature transistor did not turn onLook Ahead test for A2 volts less Motor field current is too low during Capacitor volts are low before the lineContactor closes Controller motor current sensor Input too low during runningLine driver input P2-17 is less Description Armature current exceeds Armature transistor limitVerify connection between the master control P21 Traction Status Code Symptom Temperature TMM Status CodesSteer Plug P5 pump is shorted to positive Plug P8 pump is shorted to positive Corrective Actions TROUBLE-SHOOTING Diagram YES Symptom PumpPossible Cause Transistor is over temperature Open thermal protector TP1 orNo power to pump motor Pump Controller motor currentSensor input is missing Control rangePower Transistor Q1 did not Power Transistor Q1 did not turn onTurn off properly With no pump contactor, controlCapacitor volts are low after the line Contactor closesController motor current Sensor input voltage polarityCheck Battery voltage is less than Voltage at capacitor 1C is less than VoltsTMM7A 3 TMM Pump Control Connections TMM7A Outline DrawingsAdjustable Features START-UP Display SequenceAccessing Stored Status Codes With GE Handset ActionRemarks Function Function 10 Field Current for Regen Battery Volts Battery volts Set unitsInternal Resistance Compensation Function 16 Stall Trip Point with % ON-TIME PushFunction 19 Maintenance Code Tens and Units Hours SET Function 25 MonitorFunction 26 Base Ratio Function 49 Mode 1 Field Weakening Start Push Function 51 Mode 1 MAX Armature % onFunction 28 Stored Status Code Count Pointer Push Function 52 Mode 2 Armature Controlled Acceleration Function 55 Mode 2 MAX Armature % onFunction 57 Mode 3 Field Weakening Start Function 59 Mode 3 MAX Armature % onSummary of Current Limit Adjustments Field CurrentFunction Current Limit Function 14 not ApplicableFunction 16 Speed / Torque Compensation Speed / Torque Compensation Table Voltage Setting Function 48 Mode 1 Controlled Acceleration PushFunction 49 Mode 1 Speed Limit 2 SL2 Push Function 50 Mode 1 Speed Limit 3 SL3Function 53 Mode 2 Speed Limit 2 SL2 Function 54 Mode 2 Speed Limit 3 SL3Function 55 not Applicable Function 59 not ApplicableDash Displays ApplicationStandard Dash Displays ConnectionsStart-Up Display Sequence Outline DrawingsTurn Angle Potentiometer Installation SetupOperation Degree Potentiometer for Steer Angle Input Degree Potentiometer Left Right RS-232 Memory MAP Tables Traction ControlRestrictions Function Reset to Zero Only Stored Status Code #5 Reset to Zero Only Stored Status Code #6Reset to Zero Only HoursTens/Ones Reset to Zero Only HoursThou/HunReset to Zero Only Stored Status Code #16 Reset to Zero Only Dash Display CA-1 Dash Display FWS-1None Dash Display Ratio2-1 None