GE IC3645SR4U404N2 operation manual Hourmeter Readings, a Maintenance Alert & Speed Limit, Handset

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BASIC OPERATION AND FEATURES

SX TRANSISTOR CONTROL

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Section 2.3.3 Hourmeter Readings

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.

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.

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:

•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

This feature is used when the Battery Discharge Indicator is present. Adjustment of this function will improve the accuracy of the BDI.

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.

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.

Section 2.3.6 RS 232 Communication Port

This serial communication port can be used with 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.

Section 2.3.6.a Interactive Dash Display

Modes

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.

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 2.3.7 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.

Section 2.3.8 Truck Management Module (TMM)

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.

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.

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 2.4 Hydraulic Pump Control

This hydraulic motor controller consists of the following features:

January 2000

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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 Outline DRAWINGS, Elementary Drawings and INPUTS/OUTPUTS Part NumberArgument 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 GuidelinesCleaner Reconnect plugs328A1777G1 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 onStart switch fails to close Accelerator depressed with noDirection selected KEY Negative Directional switches are closed at Both the forward and reverseSame time Initial key switch closure Start switch closed on power up afterDischarged 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 Open thermal protector TP or Transistor over temperatureLow Motor armature offset voltage is tooArmature 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 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 Symptom PumpPossible Cause 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 lineController motor current Sensor input voltage polarityCheck 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 FeaturesAccessing Stored Status Codes With GE Handset ActionRemarks Function Function 10 Field Current for Regen Battery volts Set units Battery VoltsInternal 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 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 Current Limit Function 14 not ApplicableFunction 16 Speed / Torque Compensation 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 SequenceTurn 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 #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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