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GE IC3645SP4U400N3, IC3645SR4U404N2 -69 The power steering coil current is too , -76 Capacitor (1C) voltage too high. This status code will be displayed when the voltage on the

1 74

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DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 39

January 2000

TRACTION

STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

-69 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.

MEMORY RECALL

YES CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

Circuits valid

for

Traction

Controller

SYMPTOM

Control will not operate.

POSSIBLE CAUSE

•=Shorted power steering control coil

•=Short between wires connecting to the

power steering coil (wire # 10 and 60)

If the power steering coil resistance is correct

then:

•=Defective control. Replace control unit

KEY SWITCH

L

P7

P1

P17 P2 P6 P9

P3 P12P8

P4 P5

SEAT SW.

START SW.

FOR. SW.

REV.

SW.

P10

P18

PY7

PY12

PY10

PY11

SP

P1

P5

P4

P2

FU7

TO

ACCESSORIES

FU6 P3

OSCILLATOR CARD

LEFT CONTROL

FU1

STEER

ANGLE

POT

LINE

POWER

CONNECTIONS

LEFT CONTROL

POS A1 F1

NEG A2 F2

FIELD

ARMATURE

ACC POT BDI INTERRUPT

+

-

SP

SP

FU4

A1

FU2

P

P

POWER

CONNECTIONS

RIGHT CONTROL

POS A1 F1

NEG F2

FIELD

ARMATURE

FU5

BRAKE SW.

A2

TRACTION

STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

-76 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.

MEMORY RECALL

YES CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

Circuits valid

for

Traction

Controller

SYMPTOM

Line contactor opens and closes, then

opens and can only close by opening

and closing the key switch.

POSSIBLE CAUSE

•=Unplugging the battery connector

during regenerative braking.

•=Line contactor bouncing open during

regen.

•=Main power fuse opening during

regen.

•=Intermittent battery plug connection.

* Limit Voltage:

Limit Batt.

50V 36V

70V 48V

96V 72/80V

KEY SWITCH

L

P7

P1

P17 P2 P6 P9

P3 P12P8

P4 P5

SEAT SW.

START SW.

FOR. SW.

REV.

SW.

P10

P18

PY7

PY12

PY10

PY11

SP

P1

P5

P4

P2

FU7

TO

ACCESSORIES

FU6 P3

OSCILLATOR CARD

LEFT CONTROL

FU1

STEER

ANGLE

POT

LINE

POWER

CONNECTIONS

LEFT CONTROL

POS A1 F1

NEG A2 F2

FIELD

ARMATURE

ACC POT BDI INTERRUPT

+

-

SP

SP

FU4

A1

FU2

P

P

POWER

CONNECTIONS

RIGHT CONTROL

POS A1 F1

NEG F2

FIELD

ARMATURE

FU5

BRAKE SW.

A2

Contents

Main Page Page Section 1. INTRODUCTION Page Page Page =Look ahead =Look again =Automatic look again and reset =The control monitors both armature and field FET's at =The control will not allow the line contactor to close at =Displays 100 to 0 percent charge. =Display blinks with 20% charge. Disables pump circuit =Monitor existing system status codes for both traction =Monitor battery state of charge, if available. =Monitor hourmeter reading on traction and pump =Three speeds, adjustable from O to 100% motor Section 3.0 ORDERING INFORMATION, ELEMENTARY AND OUTLINE DRAWINGS Page OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS Section 3.3 Traction Elementary FORWARD SW. START SW. SEAT SW. *** PL2-10 Page January 2000 Section 4.0 TROUBLESHOOTING AND DIAGNOSTIC STATUS CODES The following Dos and Donts should be observed =Digital tachometers and resolvers =Dash display cabling =RS-232 cabling =Analog and digital signals greater than 15 V DC and =DC switching signals greater than 15 V =Signals with currents greater than 250 mA and less than =DC busses less than 10 A =Contactor coils less than 10 A =Machine fields less than 10 A =Motor armature loops =DC outputs 10 A and above =Motor field loops 10 A and above Pow-R- WasH Nye Nye NyeNye Page NONE Segments do not illuminate on the -01 No seat switch or deadman switch TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION initial power up. This status code will be displayed when P4 is greater initial power up. This status code will be displayed when P5 is greater -02 Forward directional switch is closed on than 60% of battery voltage at initial key switch on. -03 Reverse directional switch is closed on TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION than 60% of battery voltage at initial key switch on. -05 Start switch fails to close. This status code will be displayed when P7 is less -06 Accelerator depressed with no -07 Accelerator input voltage too high on -08 Accelerator input voltage too low on -09 Both the forward and reverse -10 Steer angle potentiometer voltage is -11 Start switch closed on power up after -12 Steer angle potentiometer voltage is TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION card is mis-adjusted. This status code will be displayed when the battery -15 Battery voltage is too low or control volts are less than 1.95 volts per cell at initial key switch on. See table below. -16 Battery voltage is too high or control TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION volts are greater than 2.4 volts per cell at initial key switch on. See table below. -23 Motor field current is high on start up in draw in the motor field is too high at start up in the reverse direction. -24 Motor field current is high on start up in TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION draw in the motor field is too high at start up in the forward direction. -27 Controls power supply is less than 10 power supply is less than 10 volts. -28 Motor field current is too high during TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION draw in the motor field is sustained above a preset limit for longer than 70 seconds. -29 Motor field current is too high during the run mode (Dual motor proportioning controls only) MEMORY RECALL YES CORRECTIVE ACTIONS Circuits valid for Traction Controller SYMPTOM Control will not operate. -30 PMT enable signal from auxiliary control to master at PL21 is missing during SRO check (Dual motor proportioning controls only) MEMORY RECALL NO CORRECTIVE ACTIONS Circuits valid for Traction Controller SYMPTOM Auxiliary control shutdown. -41 Open thermal protector (TP) or transistor over temperature. This status code will be displayed when the voltage at high. This status code will be displayed when the voltage at -42 Motor armature offset voltage is too the thermal protector is too high. -43 Motor armature offset voltage is too TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION properly. This status code will be displayed when, during -44 Armature transistor did not turn off low. This status code will be displayed when the voltage at -45 Armature transistor did not turn on -46 Look Ahead test for A2 volts less MEMORY RECALL TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -49 Motor field current is too low during the TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION contactor closes. This status code will be displayed during key on run mode. This status code will be displayed when the current draw in the motor field is too low during the run mode. -57 Controller motor current sensor input from the current sensor is too low during running. MEMORY RECALL TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -65 The line coil current is too high -66 The field current exceeds the MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM Circuits valid for Traction Controller -67 The armature current exceeds the transistor exceeds its specific current limit. The control is reset by recycling the key switch. January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -68 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. MEMORY RECALL YES CORRECTIVE ACTIONS Circuits valid for Traction Controller -69 The power steering coil current is too -76 Capacitor (1C) voltage too high. This status code will be displayed when the voltage on the high during the run mode. This status code will be displayed when the current in the -77 Motor current is detected during -82 When armature motor current is greater regenerative braking. This status code will be displayed when motoring current is -90 Traction motor temperature has -91 Pump motor temperature has -93 Steering pump motor brush wear -94 Traction motor brush wear indicator -95 Pump motor brush wear indicator has -99 Maintenance alert and speed limit. This status code will be displayed when the normal -117 Card Type selection is invalid. This status code will be displayed when the card type NO GRAPHIC FOR THIS STATUS CODE -127 Control logic card power supply is less -128 Armature current is too high during the -141 Open thermal protector (TP1) or -142 Pump Controller motor current -143 Pump Controller motor current -144 Power Transistor (Q1) did not -145 Power Transistor (Q1) did not turn on TRANSISTOR PUMP CONTROL Page 50 -146 Look Ahead test for T2 volts =Check for loose connection at P1. January 2000 contactor closes. This status code will be displayed when the capacitor voltage -151 NO CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM Circuits valid for Pump Controller -157 Controller motor current STATUS CAUSE OF STATUS INDICATION -180 Voltage at capacitor (1C) is less than -181 Battery voltage is less than 14 Page Page Section 6. SX FAMILY GE HANDSET INSTRUCTIONS =Battery Voltage ( 36/48 volts is auto ranging ) =Selection of Card Operation Type. SET-UP MODE 8 8 8 8 125 0 8 5 125 LX g 1 5 + + 9 13 2 6 10 14 Page Page [( =Pick up steer pump contactor on seat switch closure =Pick up steer pump contactor on directional switch ( [ Page Page ADJUSTABLE FEATURES ZERO SX TRANSISTOR CONTROLS Page 63 January 2000 FIELD CURRENT ARMATURE CURRENT Page Page Page =LED graphics to display Battery Discharge Indication g =Various LED indicators for Maintenance Required Status =A push-button associated with the four segment LED that IC3645LXTDD T 3 + - g PY3 PY4 PY2 PY1 PY5 PY3 PY4 PY2 PY1 Wiring connections to "Y" plugs of Traction & Pump controls. Section 8.0 TURN ANGLE POTENTIOMETER INSTALLATION LEFT TURN RIGHT TURN 320 DEGREE POTENTIOMETER FOR STEER ANGLE INPUT Figure 2