GE IC3645SR4U404N2, IC3645SP4U400N3 operation manual TMM7A

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INSTALLATION AND OPERATION MANUAL

SX TRANSISTOR CONTROL

Page 53

Section 5. TRUCK MANAGEMENT MODULE (TMM) Section 5.1 General Features

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.

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.

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.

Note: Motor armature must be in the positive side of the battery circuit.

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

Pump

 

 

Card

Control

Status

 

Terminal

Terminal

Code

Connect To

TB1

P16

90 *

Neg

TB3

P11

91

Neg

TB4

P15

92

Neg

TB5

P3

93 *

Pos

TB6

P4

93 *

Pos

TB8

P5

94

Pos

TB10

P6

94

Pos

TB11

P8

95

Pos

TB12

P9

95

Pos

*Status codes 90 and 93 can also be programmed with the Handset to reduce the speed of the truck from 100 to 0 percent-on-time.

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.

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

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.

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

Section 5.4.1 TMM7A Card Connections

 

PLUG Y

9

8

10

TMM7A CARD CONNECTIONS

 

 

2

 

 

 

 

7

 

9

 

 

 

 

 

 

14

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

3

4

5

6

 

8

 

10

11

12

13

 

15

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

3

4

A1-1

A1-2

A2-1

A2-2

A3-1

A3-2

 

 

 

 

 

 

BATTERY

 

 

5

6

8

10

11

12

NEGATIVE

 

 

 

 

 

 

 

 

BATTERY

 

 

 

 

 

 

 

 

POSITIVE

 

 

 

 

 

 

 

 

Section 5.4.2 Typical Brush Wear Sensor Connections

BRUSH WEAR SENSOR CONNECTIONS (TYPICAL)

2

7

9

14

1 3 4 5 6 8 10 11 12 13 15

1

ARM

2

1

ARM

2

1

ARM

2

 

1

 

 

2

 

 

3

 

TRACTION

 

PUMP

 

PWR STEER

January 2000

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Page 52 Page 54
Contents Installation and Operation Table of Contents 41-45 20-4046-52 57-62Motor Characteristics Basic Operation and FeaturesSolid-State Reversing More Features with Fewer ComponentsFlexible System Application Slows with the increase of current in the field1.c Control Acceleration 1.b Creep Speed2 Current Limit 3.c Pedal Position Plug Braking4.b Speed Limits 6 Steer Pump Contactor Time Delay4.c Proportional Operation for Dual Motor Vehicles 5 Ramp Operation 5a Ramp Start7 On-Board Coil Drivers & Internal Coil Suppression Diagnostics 1 Systems DiagnosticsSystem Protective Override 1 Static Return to Off SRO 2 Accelerator Volts Hold Off4 Battery Discharge Indication BDI 3.a Maintenance Alert & Speed Limit3 Hourmeter Readings 4.a Internal Resistance CompensationBasic Operation and Features Argument Outline DRAWINGS, Elementary Drawings and INPUTS/OUTPUTSPart Number Outline SX-3 and SR-3 Package Size Drawings and INPUTS/OUTPUTS Section DRAWINGS, Elementary Drawings and INPUTS/OUTPUTS ControlPIN Connections to Main Plug 23 PIN and Y Plug 12 PINDiagnostic Status Codes Medium-Power Signals Level MP High-Level Signals Level H2.d. High Power Signals Level HP Cable Spacing Guidelines328A1777G1 CleanerReconnect plugs General Troubleshooting Instructions Traction Control Codes No seat switch or deadman switchTraction Status CodeDescription of Status Cause of Status Indication Reverse directional switch is closed onDirection selected Start switch fails to closeAccelerator depressed with no KEY Negative Same time Directional switches are closed atBoth the forward and reverse Initial key switch closure Start switch closed on power up afterDischarged battery Forward direction Motor field current is high on start upReverse direction Motor field current is too high during Volts DC Power supply is less than 10 voltsRun mode Traction Controller Slave/auxiliary control Open thermal protector TP or Transistor over temperatureLow Motor armature offset voltage is tooArmature transistor did not turn off ProperlyLook Ahead test for A2 volts less Than 12% of battery voltsArmature transistor did not turn on Contactor closes Motor field current is too low duringCapacitor volts are low before the line Line driver input P2-17 is less Controller motor current sensorInput too low during running Description Armature transistor limit Armature current exceedsVerify connection between the master control P21 Traction Status Code Symptom TMM Status Codes TemperatureSteer Plug P5 pump is shorted to positive Plug P8 pump is shorted to positive Corrective Actions TROUBLE-SHOOTING Diagram YES Possible Cause SymptomPump Open thermal protector TP1 or Transistor is over temperaturePump Controller motor current No power to pump motorSensor input is missing Control rangePower Transistor Q1 did not turn on Power Transistor Q1 did notTurn off properly With no pump contactor, controlContactor closes Capacitor volts are low after the lineCheck Controller motor currentSensor input voltage polarity Voltage at capacitor 1C is less than Volts Battery voltage is less thanTMM7A TMM7A Outline Drawings 3 TMM Pump Control ConnectionsSTART-UP Display Sequence Adjustable FeaturesRemarks Accessing Stored Status Codes With GE HandsetAction Function Function 10 Field Current for Regen Battery volts Set units Battery VoltsInternal Resistance Compensation Function 16 Stall Trip Point with % ON-TIME PushFunction 26 Base Ratio Function 19 Maintenance Code Tens and Units Hours SETFunction 25 Monitor Function 28 Stored Status Code Count Pointer Push Function 49 Mode 1 Field Weakening Start PushFunction 51 Mode 1 MAX Armature % on Function 55 Mode 2 MAX Armature % on Function 52 Mode 2 Armature Controlled AccelerationFunction 57 Mode 3 Field Weakening Start Function 59 Mode 3 MAX Armature % onField Current Summary of Current Limit AdjustmentsFunction 16 Speed / Torque Compensation Function Current LimitFunction 14 not Applicable Function 48 Mode 1 Controlled Acceleration Push Speed / Torque Compensation Table Voltage SettingFunction 49 Mode 1 Speed Limit 2 SL2 Push Function 50 Mode 1 Speed Limit 3 SL3Function 54 Mode 2 Speed Limit 3 SL3 Function 53 Mode 2 Speed Limit 2 SL2Function 55 not Applicable Function 59 not ApplicableApplication Dash DisplaysStandard Dash Displays ConnectionsOutline Drawings Start-Up Display SequenceOperation Turn Angle Potentiometer InstallationSetup Degree Potentiometer for Steer Angle Input Degree Potentiometer Left Right Restrictions Function RS-232 Memory MAP TablesTraction Control Reset to Zero Only Stored Status Code #6 Reset to Zero Only Stored Status Code #5Reset to Zero Only HoursTens/Ones Reset to Zero Only HoursThou/HunReset to Zero Only Dash Display CA-1 Dash Display FWS-1 Reset to Zero Only Stored Status Code #16None Dash Display Ratio2-1 None
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