INSTALLATION AND OPERATION

SX TRANSISTOR CONTROL Page 1

SEPARATELY EXCITED (SX) TRANSISTORIZED TRACTION MOTOR CONTROL

AND SERIES PUMP MOTOR CONTROL
INSTALLATION AND OPERATION MANUAL
(IC3645SR4W746N5 and IC3645SP4U450N10)

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

General Electric Company October 2002

Section 1.0 INTRODUCTION .........................................................................................................................................................4

1.1 Motor Characteristics...............................................................................................................4

1.2 Solid-State Reversing................................................................................................................5
1.3 Flexible System Application .....................................................................................................5
1.4 More Features with Fewer Components................................................................................. 5

Section 2.0 FEATURES OF SX FAMILY OF MOTOR CONTROLLERS .....................................................................................6

2.1 Performance ..............................................................................................................................6

2.1.1 Oscillator Card Features...................................................................................................6
2.1.1.a Standard Operation ...................................................................................................6
2.1.1.b Creep Speed ...............................................................................................................6
2.1.1.c Controlled Acceleration and 1A Time .....................................................................6
2.1.2 Current Limit .......................................................................................................................6
2.1.3 Braking................................................................................................................................6
2.1.3.a Plug Braking...............................................................................................................6
2.1.3.b Regenerative Braking to Zero Speed.......................................................................6

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Table of Contents ( Continued )

2.1.3.c Pedal Position Plug Braking.....................................................................................6

2.1.3.d Auto Braking ..............................................................................................................6
2.1.3.e Brake Pedal Regenerative Braking..........................................................................6
2.1.4 Auxiliary Speed Control ....................................................................................................6
2.1.4.a Field Weakening ................................................................................................................6
2.1.4.b Speed Limits ......................................................................................................................7
2.1.5 Ramp Operation .................................................................................................................7
2.1.5.a Ramp Start..................................................................................................................7
2.1.5.b Anti-Rollback..............................................................................................................7
2.1.6 On-Board Coil Drivers and Internal Coil Suppression .................................................7
2.2 System Protective Override......................................................................................................7
2.2.1 Static Return to Off (SRO) ................................................................................................7
2.2.2 Accelerator Volts Hold Off ...............................................................................................7
2.2.3 Pulse Monitor Trip (PMT) .................................................................................................7
2.2.4 Thermal Protector (TP)................................... ..................................................................7
2.2.5 Low Voltage .......................................................................................................................7
2.3 Diagnostics................................................ ................................................................................8
2.3.1 Systems Diagnostics.........................................................................................................8
2.3.2 Status Codes............................................. .........................................................................8
2.3.2.a Standard Codes........................................ .................................................................8
2.3.2.b Stored Codes ......................................... ....................................................................8
2.3.3 Hourmeter Readings .........................................................................................................8
2.3.3.a Maintenance Alert and Speed Limit .................... ...................................................8
2.3.4 Battery Discharge Indication (BDI)....................... ..........................................................8
2.3.4.a Internal Resistance Compensation ..................... ...........................................................8
2.3.5 Handset ..............................................................................................................................8
2.3.6 RS-232 Communication Port ............................... ............................................................8
2.3.6.a Dash Display Interaction Modes ................... ................................................................8
2.3.7 Circuit Board Coil Driver Modules...................................................................................9
2.3.8 Truck Management Module (TMM)................................................................................9
2.4 Hydraulic Pump Control............................................................................................................9

Section 3.0 ORDERING INFORMATION, ELEMENTARY AND OUTLINE DRAWINGS ......................................................10

3.1 Ordering Information for Separately Excited Controls ................................................................. 10

3.2 Outline: SX-4 Package Size ..............................................................................................................11
3.3 Outline: SX-3 and SR-3 Package Size .............................................................................................12
3.4 Traction Elementary..........................................................................................................................13
3.5 Pump Elementary...............................................................................................................................14
3.6 Traction and Pump Control Input / Output List..............................................................................15

Section 4.0 TROUBLESHOOTING AND DIAGNOSTIC STATUS CODES ..............................................................................16

4.1 General Maintenance Instructions .................................................................................................16

4.2 Cable Routing and Separation ................................................................................................16
4.2.1 Application Responsibility ................................................................................................16
4.2.2 Signal/Power Level Definitions ................................................................................................16
4.2.2.a Low Level Signals (Level L)...............................................................................................16
4.2.2.b High Level Signals (Level H) .............................................................................................17
4.2.2.c Medium-Power Signals (Level MP).................................................................................17
4.2.2.d High-Power Signals (Level HP)........................................................................................17
4.2.3 Cable Spacing Guidelines.........................................................................................................17
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Table of Contents ( Continued )

4.2.3.a General Cable Spacing .....................................................................................................17
4.2.4 Cabling for Vehicle Retrofits ....................................................................................................17
4.2.5 RF Interference ..........................................................................................................................17
4.2.6 Suppression ...............................................................................................................................17
4.3 Recommended Lubrication of Pins and Sockets Prior to Installation ........................................18
4.4 Controller Mounting Guidelines.......................................................................................................19
4.4.1 Necessary Tools........................................................................................................................19
4.4.2 The GE Control Mounting Surface ..........................................................................................19
4.4.3 Vehicle Mounting Surface........................................................................................................19
4.4.4 Application of Thermal Compound..........................................................................................19
4.4.5 Mounting the GE Control ..........................................................................................................20
4.4.6 Maintenance ..............................................................................................................................20
4.5 General Troubleshooting Instructions............................................................................................20-21
4.6 Traction Controller Status Codes ....................................................................................................22-38
4.7 TMM Module Status Codes .............................................................................................................39-43
4.8 Pump Control Status Codes .............................................................................................................44-50

Section 5.0 TRUCK MANAGEMENT MODULE (TMM) ............................................................................................................51

5.1 General Features ............................................... ...............................................................................51

5.2 Operation ...........................................................................................................................................51
5.3 Installation.................................................... .....................................................................................51
5.4 Connection Diagrams .......................................................................................................................51
5.4.1 TMM7A Card Connections.......................................................................................................51
5.4.2 TMM7A Typical Brush Wear Sensor Connections ............ ..................................................51
5.4.3 TMM Pump Control Connections ........................... ................................................................52
5.5 TMM7A Outline Drawings................................................................................................................52

Section 6.0 SX FAMILY - GE HANDSET INSTRUCTIONS.......................................................................................................53

6.1 General Features ......................................... .....................................................................................53

6.2 Purpose/Setup Functions .................................. .............................................................................53
6.3 Setup Function Procedures .............................................................................................................54
6.3.1 Setup Mode ............................................ ...................................................................................54
6.3.2 Status Code Scrolling.................................. .............................................................................54
6.3.3 SX Handset Plug Connections & Outline Drawing.... ............................................................54
6.4 Setup Functions for Traction Controller .. ......................................................................................55-60
6.5 Summary of Current Limit Adjustments ..........................................................................................61
6.6 Setup Functions for Hydraulic Pump Controller ...........................................................................62-64

Section 7.0 DASH DISPLAYS........................................................................................................................................................65

7.1 Application ...........................................................................................................................................65

7.2 Standard Dash Displays .....................................................................................................................65
7.3 Interactive Dash Displays................................ ...................................................................................65
7.4 Start-up Display Sequence ............................... .................................................................................66
7.5 Outline Drawings .................................................................................................................................66

Section 8.0 MEMORY MAPS ........................................................................................................................................................67

8.1 Typical Memory Map for Traction Control ....................................................................................67-69

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Section 1. INTRODUCTION current to increase, providing the greater torque needed to

drive the increased mechanical load. If the mechanical
Section 1.1 Motor Characteristics load is decreased, the process reverses. The motor speed
and the back EMF increase, while the armature current and
The level of sophistication in the controllability of traction the torque developed decrease. Thus, whenever the load
motors has changed greatly over the past several years. changes, the speed changes also, until the motor is again
Vehicle manufacturers and users are continuing to expect in electrical balance.
more value and flexibility in electric vehicle motor and
control systems as they are applied today. In order to In a shunt motor, the variation of speed from no load to
respond to these market demands, traction system normal full load on level ground is less than 10%. For this
designers have been forced to develop new approaches to reason, shunt motors are considered to be constant speed
reduce cost and improve functions and features of the motors (Figure 2).
overall system. Development is being done in a multi-
generational format that allows the market to take
advantage of today’s technology, while looking forward to SPEED

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

LOAD CURRENT

STARTING
offers many of the features that are generally found on the

CURRENT
FULL
NO LOAD CURRENT
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. TORQUE
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, ARMATURE CURRENT
Figure 2
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 In the separately excited motor, the motor is operated as a
combined. 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
SPEED
motor (Figure 3.)
NO LOAD CURRENT

LOAD CURRENT

STARTING
CURRENT
FULL

SPEED

TORQUE

ARMATURE CURRENT
Figure 1
LOAD CURRENT
FULL
NO LOAD CURRENT

As shown in from the typical performance curves of Figure

STARTING
CURRENT

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 ARMATURE CURRENT
voltage source and is therefore independent of variations in Figure 3
load and armature current. If field strength is held
constant, the torque developed will vary directly with the
Aside from the constant horsepower characteristics
armature current. If the mechanical load on the motor
described above, there are many other features that
increases, the motor slows down, reducing the back EMF
provide increased performance and lower cost. The
(which depends on the speed, as well as the constant field
strength). The reduced back EMF allows the armature
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following description provides a brief introduction to armature, the motor performance curve can be maximized
examples of some of these features. 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 Field weakening with a series wound motor is
determined by the direction in which current flows through accomplished by placing a resistor in parallel with the field
the field windings. Because of the of the shunt motor field winding of the motor. Bypassing some of the current
only typically requires about 10% of the armature current at flowing in the field into the resistor causes the field current
full torque, it is normally cost effective to replace the to be less, or weakened. With the field weakened, the motor
double-pole, double-throw reversing contactor with a low speed will increase, giving the effect of “overdrive”. To
power transistor H-Bridge circuit (Figure 4). 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
LINE POS
infinite adjustments of “overdrive” levels, between
FUSE motor base speed and maximum weak field. The
desirability of this feature is enhanced by the
Q5
elimination of the contactor and resistor required for
Q3
A1 +
field weakening with a series motor.
ARM F1 F2
CAP Q2
A2 -
With a separately excited motor, overhauling speed
Q4 Q6 limit, or downhill speed, will also be more constant. By
Q1
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
NEG
slows with the increase of current in the field.
Figure 4

Regenerative braking (braking energy returned to the

By energizing the transistors in pairs, current can be made battery) may be accomplished completely with solid-state
to flow in either direction in the field. The armature control technology. The main advantage of regenerative braking is
circuit typically operates at 12KHZ to 15KHZ, a frequency increased motor life. Motor current is reduced by 50% or
range normally above human hearing. This high frequency more during braking while maintaining the same braking
coupled with the elimination of directional contactors, torque as electrical braking with a diode clamp around the
provides very quiet vehicle operation. The field control armature. The lower current translates into longer brush
circuits typically operate at 2 KHZ. life and reduced motor heating. Solid state regenerative
braking also eliminates a power diode, current sensor and
The line contactor is normally the only contactor required contactor from the circuit.
for the shunt motor traction circuit. This contactor is used
for both pre-charge of the line capacitors and for For GE, the future is now as we make available a new
emergency shut down of the motor circuit, in case of generation of electric traction motor systems for electric
problems that would cause a full motor torque condition. vehicles having separately excited DC shunt motors and
The line can be energized and de-energized by the various controls. Features that were once thought to be only
logic combinations of the vehicle, i.e. activate on key, seat available on future AC or brushless DC technology vehicles
or start switch closure, and de-energize on time out of idle systems are now achievable and affordable.
vehicle. Again, these options add to the quiet operation of
the vehicle.

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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Section 2. FEATURES OF SX FAMILY OF TRANSISTOR current is usually greater than battery current, except at
MOTOR CONTROLLERS 100% ON time.

Section 2.1 Performance Section 2.1.3 Braking

Section 2.1.1 Oscillator Card Features Section 2.1.3.a Plug Braking

Section 2.1.1.a Standard Operation Section 2.1.3.b Regenerative Braking to Zero Speed

With the accelerator at maximum ohms or volts, the creep Slow down is accomplished when
speed can be adjusted by Function 2 of the Handset or a reversing direction by providing a
trimpot. The field control section allows the adjustment of small amount of retarding torque for
the field weakening level in order to set the top speed of the Q2 deceleration. If the vehicle is
motor. This top speed function (Minimum Field Current) is ARM moving, and the directional lever is
enabled when the armature current is less than the value moved from one direction to the
set by Function 24 and the accelerator input voltage is less other, the regen signal is initiated.
than 1 volt. Top Speed can be adjusted by Function 7 of the Once the regen signal has been
Q1
Handset or a trimpot. initiated, the field current is
The percent on-time has a range of approximately 0 to 100 Figure 5 increased (armature circuit shown in
percent. The SX controllers operate at a constant Figure 5). Armature current is
frequency and the percent on-time is controlled by the regulated to the regen current limit as set by Function 9. As
pulse width of the voltage / current applied to the motor the vehicle slows down, the field current continues to
circuits. increase, and transistor Q2 begins to chop. The field
current will increase until it reaches a preset value set by
Section 2.1.1.b Creep Speed Function 10, and transistor Q2 on-time will increase until it
reaches 100% on-time. Once both of the above conditions
With the accelerator at maximum ohms or volts have been met, and regen current limit can no longer be
(approximately 3.7 to 3.5 VDC), the creep speed can be maintained, the braking function is canceled. The fields
adjusted by Function 2 of the Handset. At creep speed, the will then reverse, and the control reverts back to motoring.
ON time can decrease to approximately 5%, with the OFF Part of the energy produced by the motor during regen is
time at approximately 95%. At full transistor operation, this returned to the battery, and part is dumped in the motor as
condition will be reversed (short OFF time, long ON time). heat.
This variation of ON and OFF time of the oscillator varies
the voltage applied to the motor, thereby varying the speed Section 2.1.3.c Pedal Position Plug Braking
of the motor for a given load.
This feature allows control of the plugging distance based
Section 2.1.1.c Control Acceleration and 1A Time on pedal position when there has been a “directional
switch" change. Pedal position will reduce the regenerative
This feature allows for adjustment of the rate of time it current to the "value set by this function" as the accelerator
takes for the control to accelerate to 100% applied battery is returned to the creep speed position. Maximum regen
voltage to the motor on hard acceleration. The 1A current is obtained with the accelerator in the top speed
contactor will automatically close 2.0 seconds after the position.
controlled acceleration stops and the accelerator input is
less than 0.5 volts, or less than 200 ohms. Armature C/A is Section 2.1.3.d Auto Braking
adjusted by Function 3 from 0.1 to 22 seconds.
This feature is enabled by initiating a "neutral position"
Section 2.1.2 Current Limit using either the directional switch or the accelerator
switch. Once activated, Auto Braking operates similar to
This circuit monitors motor current by utilizing sensors in Pedal Position Plug Braking and is adjusted by using
series with the armature and field windings. The Function 21 of the Handset.
information detected by the sensor is fed back to the card
so that current may be limited to a pre-set value. If heavy Section 2.1.4 Auxiliary Speed Control
load currents are detected, this circuit overrides the
oscillator and limits the average current to a value set by Section 2.1.4.a Field Weakening
Function 4 and Function 8 of the Handset. The C/L setting is
based on the maximum thermal rating of the control. This function allows the adjustment of the field weakening
Because of the flyback current through 3REC, the motor level in order to set the top speed of the motor. The function
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is enabled when the armature current is less than the value control shuts off and cannot be restarted until the
set by Function 24 and the accelerator input voltage is less directional lever is returned to neutral. A time delay of
than 1 volt. It is important to note that this function is used approximately 2 seconds is built into the seat switch input
to optimize motor and control performance, and this setting to allow momentary opening of the seat switch, if a bump is
will be determined by GE and OEM engineers at the time of encountered.
vehicle development. This setting must not be changed by
field personnel, without the permission of the OEM. Section 2.2.2 Accelerator Volts Hold Off

Section 2.1.4.b Speed Limits This feature checks the voltage level at the accelerator
input whenever the key switch or seat switch is activated.
This feature provides a means to control speed by limiting If, at start up, the voltage is less than 3.0 volts, the control
motor volts utilizing three "adjustable speed limits. This will not operate. This feature assures that the control is
motor volt limit regulates top speed of the transistor calling for low speed operation at start up.
controller, but actual truck speed will vary at any set point
depending on the loading of the vehicle. Each speed limit Section 2.2.3 Pulse Monitor Trip (PMT)
can be adjustable with the Handset using Functions 12 and
13. The PMT design contains three features which shut down,
or lock out, control operation if a fault conditions occurs
Section 2.1.5 Ramp Operation that would cause a disruption of normal vehicle operation:

Section 2.1.5a Ramp Start · Look ahead

· Look again
This feature provides maximum control torque to restart a · Automatic look again and reset
vehicle on an incline. The memory for this function is the
directional switch. When stopping on an incline, the The PMT circuit will not allow the control to start under the
directional switch must be left in its original or neutral following conditions:
position to allow the control to initiate full power when
restarted. The accelerator potentiometer input will · The control monitors both armature and field FET's at
modulate ramp start current. start-up and during running.
· The control will not allow the line contactor to close at
Section 2.1.5b Anti-Rollback start-up, or will drop it out during running, if either the
armature or field FET's are defective, so as to cause
This feature provides retarding torque to limit rollback uncontrolled truck movement.
speed in the non-travel direction when the ACC pedal is
released when stopping on a grade, or when the brake Section 2.2.4 Thermal Protector (TP)
pedal is released when starting on a grade. This feature
forces the vehicle to roll very slowly down the grade when This temperature sensitive device is internal to the power
accelerator or brake is released. Because the vehicle can transistor (Q1) module. If the transistor's temperature
gain significant speed during roll-back, the torque needed begins to exceed the design limits, the thermal protector
to re-start on the ramp is lower than an unrestricted roll- will lower the maximum current limit, and maintain the
back speed. transistors within their temperature limits. Even at a
reduced current limit, the vehicle will normally be able to
Section 2.1.6 On-Board Coil Drivers & Internal Coil reach sufficient speed to initiate 1A operation, thereby
Suppression allowing the control to cool. As the control cools, the
thermal protector will automatically reset, returning the
Coil drivers for the LINE and 1A, or bypass, contactors are control to full power.
on-board the control card. These contactors must have
coils rated for the vehicle battery volts. Section 2.2.5 Low Voltage

Section 2.2 System Protective Override Batteries under load, particularly if undersized or more
than 80 percent discharged, will produce low voltages at
Section 2.2.1 Static Return to Off (SRO) the control terminals. The SX control is designed for use
down to 50 percent of a nominal battery voltage of 36-84
This inherent feature of the control is designed to require volts, and 75 percent of a nominal battery voltage of 24
the driver to return the directional lever to the neutral volts. Lower battery voltage may cause the control to
position anytime he leaves the vehicle and returns. operate improperly, however, the resulting PMT should
Additionally, if the seat switch or key switch is opened, the open the Line contactor, in the event of a failure.
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Section 2.3 Diagnostics Section 2.3.4 Battery Discharge Indication (BDI)

Section 2.3.1 Systems Diagnostics The latest in microprocessor technology is used to provide
accurate battery state of charge information and to supply
The control detects the system's present operating status passive and active warning signals to the vehicle operator.
and can be displayed to either the Dash Display or the Features and functions:
Handset. There are currently over 70 status codes that are · Displays 100 to 0 percent charge.
available with SX systems using Traction and Pump · Display blinks with 20% charge. Disables pump circuit
controls and Truck Management Module (TMM). Along with 10% charge. Auto ranging for 36/48 volt operation.
with the status code display from the TMM, the SX control Adjustable for use on 24 to 80 volts.
is capable of reducing the current to the motor, alerting the
operator of a critical fault condition. Section 2.3.4.a Internal Resistance Compensation

Section 2.3.2 Status Codes This feature is used when the Battery Discharge Indicator
is present. Adjustment of this function will improve the
Section 2.3.2a Standard Status Codes accuracy of the BDI.

The SX traction control has over 30 Status Codes that Section 2.3.5 Handset
assist the service technician and operator in trouble
shooting the vehicle. If mis-operation of the vehicle occurs, This is a multi-functional tool used with the LX, ZX, and SX
a status code will be displayed on the Dash Display for Series GE solid state controls. The Handset consists of a
vehicles so equipped, or be available by plugging the Light Emitting Diode (LED) display and a keyboard for data
Handset into the “y” plug of the logic card. entry. Note, for ordering purposes, a separate Handset part
With the status code number, follow the procedures is required for SX controls.
outlined in DIAGNOSTIC STATUS CODES to determine the
problem and a solution. Features and functions:
· Monitor existing system status codes for both traction
Note: The Status Code Instruction Sheets do not claim to and pump controls. Monitor intermittent random status
cover all possible causes of a display of a "status code ". codes.
They do provide instructions for checking the most direct · Monitor battery state of charge, if available.
inputs that can cause status codes to appear. · Monitor hourmeter reading on traction and pump
controls. Monitor or adjust the control functions.
Section 2.3.2.b Stored Status Codes
Section 2.3.6 RS 232 Communication Port
This feature records the last 16 "Stored Status Codes" that
have caused a PMT controller shut down and/or disrupted This serial communication port can be used with
normal vehicle operation. (PMT type faults are reset by Interactive Custom Dash Displays to allow changes to
cycling the key switch). These status codes, along with the vehicle operating parameters by the operator. Or, it can be
corresponding BDI and hourmeter readings, can be used by service personnel to dump control operating
accessed with the Handset, or by using the RS 232 information and settings into a personal computer program.
communications port and dumping the information to a
Personal Computer terminal. Section 2.3.6.a Interactive Dash Display
Modes
Section 2.3.3 Hourmeter Readings
The Interactive Custom Dash Display allows the operator to
This feature will display the recorded hours of use of the select the best vehicle performance for changing factory
traction and pump control to the Dash Display each time (task) conditions. There are four (4) "operator interaction
the key switch is turned off. modes" that can be selected by depressing a push button
on the dash display.
Section 2.3.3.a Maintenance Alert & Speed Limit
From the Dash Display, the operator may select any of four
This feature is used to display Status Code 99 and/or pre-set interactive modes consisting of (4) Controlled
activate a speed limit when the vehicle operating hours Acceleration levels, (4) Field Weakening levels and (4)
match the hours set into the maintenance alert register. Speed Limits.
This feature is set with the Handset using Functions 19 and These interactive modes are "pre-set" using the Handset
20. The operator is alerted that maintenance on the vehicle (Functions 48-62) or a personal computer (Functions 97-
is required.
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112). This feature allows the operator to select the best The three speed (motor volts) reference points P12, P19,
vehicle performance for changing factory (task) conditions. and P20 are selected by connecting these points
independently to battery negative.
Section 2.3.7 Circuit Board Coil Driver Modules
The first speed is obtained by closing Speed Limit I (P12) to
Coil drivers are internal to the control card, and are the control negative. SLl is adjustable by Function 11 using the
power devices that operate the Line and 1A contactor coils. Handset to adjust motor voltage from O to 100%. The
On command from the control card, these drivers initiate specified motor volts will be regulated, however, the
opening and closing the contactor coils. All driver modules magnitude of motor current will vary depending on the
are equipped with reverse battery protection, such that, if loading of the vehicle.
the battery is connected incorrectly, the contactors can not
be closed electrically. The second speed is obtained by closing SL2 (P19) to
control negative. SL2 is adjusted using the Handset and
Section 2.3.8 Truck Management Module (TMM) Function 12 similar to SL1.

The Truck Management Module is a multifunction The third speed is obtained by closing SL3 (P20) to control
accessory card, or an integral function of the GE Pump negative. SL3 is adjusted using the Handset and Function
controls when used with the SX Traction control. The 13 similar to SL1.
Module provides the OEM the ability to initiate status codes
or operator warning codes to be displayed on the Dash If more than one Speed Limit is activated, the selected
Display, whenever a normally open switch or sensor wire speed with the highest motor volts will override the low
provides a signal to the Module. motor volt speed. The current limit circuit is adjustable and
operates the same as the traction current limit.
The TMM Module can be used to display a separate status
code indicating over-temperature of traction motors, The controlled acceleration circuit is adjustable and
hydraulic motors, or any other device or system that can operates the same as the traction circuit. Adjustment range
activate a switch that closes. is from 0.1 to 5.5 seconds.

The TMM Module can also be used as a Brush Wear The Battery Discharge Indicator (BDI) interrupt will disable
Indicator (BWI). The Brush Wear Indicator is designed to the hydraulic controller if the connection at P10 loses the
detect a "worn out brush" and display a fault code on the 12 volt signal from the traction control. BDI interrupt can be
Dash Display to warn maintenance personnel that the disabled by Function 17 using the Handset. Select card type
motor brushes need to be replaced before they wear to the with or without BDI function.
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:
· 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.
· Coil driver module designed to operate the line
contactor (see Section 2.3.7).

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.

October 2002
OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS
SX TRANSISTOR CONTROL Page 10

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: Basic Electric Vehicle Control Number

Argument 02: Control Type:

SP = Series Control (Pump)

SH = Separately Excited Control ( Plugging )
SR = Separately Excited Control ( Regen to Zero )

Argument 03: Operating Voltage:

1 = 120 volts 4 = 48 volts

2 = 24 volts 5 = 36/48 volts
3 = 36 volts 6 = 24/36 volts
7 = 72/80 volts

Argument 04: Package Size:

D = 6.86” X 6.67”
R = 6.86” X 8.15”
U = 8.66” X 8.13”
W = 8.66” X 10.83”

Argument 05: Armature Current

( 2 characters )

22 = 220 Amps
33 = 330 Amps
40 = 400 Amps
etc.

Argument 06: Field Current

( 1 character )
2 = 20 Amps
3 = 30 Amps
4 = 40 Amps
etc.

Argument 07: Customer / Revision

A1 = Customer A / Revision 1
B1 = Customer B / Revision 1
etc.

October 2002
OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS
SX TRANSISTOR CONTROL Page 11

Section 3.2 Outline: SX-4 Package Size

October 2002
OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS
SX TRANSISTOR CONTROL Page 12

Section 3.3 Outline: SX-3 and SR-3 Package Size

October 2002
 *

FU3
3
KEY SWITCH
10
*
DIRECT
SWITCH
10

1A *
ACCEL
* START FWD REV
SW.
SX TRANSISTOR CONTROL

SEAT SW.
SP
L
Section 3.4 Traction Elementary

10
41 24 7 15 6 8
13

FU5
P18 P17 P2 P6 P3 P4 P5 PY7
PUMP
CONNECTION P1 OSC CARD CONNECTIONS PY12
POS PY10
LINE
P7 P9 P10 P15 P11 P13 P14 P20
PY11

29 30 50
TMM OVER TEMP.
13
TMM BRUSHWEAR INPUT
*
ACCEL REG BRAKING POTENTIOMETER INPUT

FU4
OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS

* SW.

FU1
43 REGEN OUTPUT SIGNAL
A1 13A
TMM7 I MOTOR (VOLTAGE OUT)
+ 88
A1 BDI INTERRUPT
F1

ARM
* *
* POS A1 F1

STEER PUMP
A2
- CONTROL POWER
TMM7 CONNECTION
*

FIELD
89
NEG A2 F2
ARMATURE
44 * F2
SP

PUMP CONNECTION
BATT NEG
MOTOR CONNECTIONS
A2 * CUSTOMER SUPPLIED

1A

October 2002
Page 13
 KEY SW. 10

FU6 12-1
L PM-2

L
TO TRACTION

FU2
10
50
BATT (+) 2
PL2-10
P
103
51
SX TRANSISTOR CONTROL

1 12
STATUS CODE 93 INPUT 3
Section 3.5 Pump Elementary

STATUS CODE 93 INPUT 4 17

A1 A1 STATUS CODE 94 INPUT 5
STATUS CODE 94 INPUT 6 18

SR-2
PM STATUS CODE 95 INPUT 8
STATUS CODE 95 INPUT 9 52
19
A2 A2 53
STATUS CODE 90 INPUT 16 20
S1
STATUS CODE 91 INPUT 11

CONTROL PLUG PL2

BRUSH WEAR OUTPUT 13
21
OVER TEMP OUTPUT 14
PY7 PY12 PY10 PY11
S2

A1 PLUG PY
CONNECTIONS

A1
SPEED 2
SPEED 1
OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS

SPEED 3

P A1
PUMP CONTROL POWER

ARMATURE
A2 * * *
CONNECTION

FU4
FU5
N A2

FIELD
13C 13C 13C
A2
PS PM-2
N
13C
BATT (-)

POWER CONNECTION

* SUPPLIED BY CUSTOMER

October 2002
Page 14
OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS
SX TRANSISTOR CONTROL Page 15

Section 3.6 Traction and Pump Control Input and Output List
CONNECTIONS TO MAIN PLUG (23 PIN) AND "Y" PLUG (12 PIN)

TRACTION PUMP
PIN INPUT/OUTPUT DESCRIPTION INPUT/OUTPUT DESCRIPTION
1 BATTERY VOLTS FROM BATTERY BATTERY VOLTS FROM BATTERY
2 BATTERY VOLTS FROM KEY BATTERY VOLTS FROM KEY
3 BATTERY VOLTS FROM START SWITCH STATUS CODE 93 INPUT
4 BATTERY VOLTS FROM FORWARD SWITCH STATUS CODE 93 INPUT
5 BATTERY VOLTS FROM REVERSE SWITCH STATUS CODE 94 INPUT
6 BATTERY VOLTS FROM SEAT SWITCH STATUS CODE 94 INPUT
7 ACCELERATOR INPUT VOLTAGE SIGNAL POTENTIOMETER INPUT VOLTAGE SIGNAL
8 NOT USED STATUS CODE 95 INPUT
9 ACCELERATOR POT +5 VOLTS SUPPLY STATUS CODE 95 INPUT
10 BDI INTERRUPT PUMP ENABLE SIGNAL 12VDC
11 PLUG/RGN OUTPUT SIGNAL +12V 1=PLUG STATUS CODE 91 INPUT
12 NOT USED SPEED LIMIT #1 INPUT
13 RGN BRAKE POTENTIOMETER INPUT TMM1 BRUSHWEAR INDICATER OUTPUT
14 TMM BRUSHWEAR TMM1 OVER TEMPERATURE OUTPUT
15 IMOTOR OUT NOT APPLICABLE
16 MOTOR CURRENT COMPENSATION STATUS CODE 90 INPUT
17 LINE CONTACTOR DRIVER AND SUPPRESSION LINE CTR DRIVER (PUMP) AND SUPPRESSION
18 1A CONTACTOR DRIVER AND SUPPRESSION 1A CONTACTOR DRIVER
19 DASH DISPLAY + 5 VOLT SUPPLY SPEED LIMIT #2 INPUT
20 TMM OVERTEMP SPEED LIMIT #3 INPUT
21 NOT USED NOT USED
22 SERIAL RECEIVE / DASH DISPLAY SERIAL RECEIVE
23 SERIAL TRANSMIT / DASH DISPLAY SERIAL TRANSMIT
MOTOR PROPORTIONING "Y" PLUG PUMP "Y" PLUG
PIN INPUT/OUTPUT DESCRIPTION INPUT/OUTPUT DESCRIPTION
1 CLOCK (OUT) CLOCK (OUT)
2 DATA (OUT) DATA (OUT)
3 ENABLE (OUT) ENABLE (OUT)
4 NEGATIVE NEGATIVE
5 +5V SUPPLY +5V SUPPLY
6 CONT/STORE (IN) (HANDSET) CONT/STORE (IN) (HANDSET)
7 EXTERNAL JUMPER TO PY12 EXTERNAL JUMPER TO PY12
8 VALUE VALUE
9 FUNCTION FUNCTION
10 EXTERNAL JUMPER TO PY11 EXTERNAL JUMPER TO PY11
11 SERIAL RECEIVE / CONNECT TO P22 SERIAL RECEIVE / CONNECT TO P22
12 SERIAL TRANSMIT / CONNECT TO P23 SERIAL TRANSMIT / CONNECT TO P23

1 2 3 4 5 6 1 2 3 4 5 6 6 8

9 10 11 12 13 14 15
7 8 9 10 11 12
16 17 18 19 20 21 22 23

WIRE END VIEW "Y" PLUG WIRE END VIEW - MAIN PLUG

October 2002
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
The transistor control, like all electrical apparatus, does tips are intact and free of contaminants.
have some thermal losses. The semiconductor junctions
have finite temperature limits, above which these devices GE does not recommend that any type of welding be
may be damaged. For these reasons, normal maintenance performed on the vehicle after the installation of the
should guard against any action which will expose the control(s) in the vehicle. GE will not honor control failures
components to excessive heat and/or those conditions during the warranty period when such failures are
which will reduce the heat dissipating ability of the control, attributed to welding while the control is installed in the
such as restricting air flow. vehicle.

The following Do’s and Don’t’s should be observed: Section 4.2 Cable Routing and Separation

Any controls that will be applied in ambient temperatures Electrical noise from cabling of various voltage levels can
over 100° F (40° C) should be brought to the attention of the interfere with a microprocessor-based control system. To
vehicle manufacturer. reduce this interference, GE recommends specific cable
separation and routing practices, consistent with industry
All external components having inductive coils must be standards.
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 The customer and customer’s representative are
dust. In oily or greasy areas, a mild solution of detergent or responsible for the mechanical and environmental
denatured alcohol can be used to wash the control, and locations of cables. They are also responsible for applying
then low-pressure air should be used to completely dry the the level rules and cabling practices defined in this section.
control. 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, On new installations, sufficient space should be allowed to
acting as an additional heat sink, will give improved vehicle efficiently arrange mechanical and electrical equipment.
performance by keeping the control package cooler. Apply
On vehicle retrofits, level rules should be considered during
a thin layer of heat-transfer grease (such as Dow Corning
the planning stages to help ensure correct application and
340) between the control heat sink and the vehicle frame.
a more trouble-free installation.
Control wire plugs and other exposed transistor control Section 4.2.2. Signal/Power Level Definitions
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
CAUTION: The vehicle should not be plugged when the
classes.
vehicle is jacked up and the drive wheels are in a free
wheeling position. The higher motor speeds can create Sections 4.2.2.a through 4.2.2.d define these levels and
excessive voltages that can be harmful to the control. 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 Low-level signals are designated as level L. These consist
rating specified for the vehicle. Follow normal battery of:
maintenance procedures, recharging before 80 percent · Analog signals 0 through ±15 V
discharged with periodic equalizing charges. · 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 The following are specific examples of level L signals used
and pump systems is recommended to occur during every in drive equipment cabling:
October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 17
· Control common tie customer must apply the general guidelines (section
· DC buses feeding sensitive analog or digital hardware 4.2.3.a), outlined below.
· All wiring connected to components associated with
sensitive analog hardware with less than 5V signals (for 4.2.3.a General Cable Spacing
example, potentiometers and tachometers)
· Digital tachometers and resolvers The following general practices should be used for all
· Dash display cabling levels of cabling:
· RS-232 cabling
· All cables and wires of like signal levels and power
Note: Signal inputs to analog and digital blocks should be levels must be grouped together.
run as shielded twisted-pair (for example, inputs from · In general, different levels must run in separate wire
tachometers, potentiometers, and dash displays). bundles, as defined in the different classes, identified
above. Intermixing cannot be allowed, unless noted by
4.2.2.b High-Level Signals (Level H) exception.
· Interconnecting wire runs should carry a level
High-level signals are designated as level H. These signals designation.
consist of: · If wires are the same level and same type signal, group
those wires from one location to any other location
· Analog and digital signals greater than 15 V DC and together in multiconductor cables or bind them
less than 250 mA together with twine or zip-ties.
· When unlike signals must cross, cross them in 90°
For example, switch inputs connected to battery volts are angles at a maximum spacing. Where it is not possible
examples of level H signals used in drive equipment to maintain spacing, place a grounded steel barrier
cabling. between unlike levels at the crossover point.

4.2.2.c Medium-Power Signals (Level MP) 4.2.4 Cabling for Vehicle Retrofits

Medium power signals are designated as level MP. These Reducing electrical noise on vehicle retrofits requires
signals consist of: careful planning. Lower and higher levels should never
encircle each other or run parallel for long distances.
· DC switching signals greater than 15 V It is practical to use existing wire runs or trays as long as
· Signals with currents greater than 250 mA and less than the level spacing (see section 4.2.2) can be maintained for
10A the full length of the run.
Existing cables are generally of high voltage potential and
The following are specific examples of level MP signals noise producing. Therefore, route levels L and H in a path
used in drive equipment cabling: separate from existing cables, whenever possible.

· DC busses less than 10 A For level L wiring, use barriers in existing wire runs to
· Contactor coils less than 10 A minimize noise potential.
· 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. To prevent radio frequency (RF) interference, care should
The following are specific examples of level HP signals be taken in routing power cables in the vicinity of radio-
used in drive equipment cabling: 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
4.2.3. Cable Spacing Guidelines example, a snubber) is required on all inductive devices
controlled by an output. This suppression minimizes noise
Recommended spacing (or clearance) between cables (or and prevents damage caused by electrical surges.
wires) is dependent on the level of the wiring inside them.
For correct level separation when installing cable, the

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 18
Section 4.3 Recommended Lubrication of Pins and 2. Locate the plug that contains the socket (female)
Sockets Prior to Installation terminals. Maintenance needs only to be performed on
the plug containing the socket (female) type terminals.
Beginning in January of 1999, GE will implement the Reconnecting the plugs will lubricate the pin (male)
addition of a lubricant to all connections using pins and terminals.
sockets on EV100/EV200 and Gen II products. Any 3. Clean each terminal using Chemtronicsâ contact
connection made by GE to the A, B, X, Y, or Z plugs will cleaner “Pow-R-WasH CZ “ as shown in Figure 1.
have the lubricant NYE 760G added to prevent fretting of
these connections during vehicle operation.

Fretting occurs during microscopic movement at

the contact points of the connection. This movement n ic s
mt r o
exposes the base metal of the connector pin which, when Che ane
r
t cle
tac
oxygen is present, allows oxidation to occur. Sufficient con

Pow H Z
build up of the oxidation can cause intermittent contact

-R-C
and intermittent vehicle operation. This can occur at any

s
Wa
similar type of connection, whether at the control or in any
associated vehicle wiring, and the resultant intermittent
e
contact can provide the same fault indication as actual ciro
zan

component failure.

The addition of the NYE 760G lubricant will prevent Figure 1

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 4. Lubricate each terminal using Nyeâ 760G lubricant as
controls at the time of their installation into a vehicle shown in figure 2. Apply enough lubricant to each
terminal opening to completely fill each opening to a
When servicing existing vehicles exhibiting depth of .125” maximum.
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
N

term reliable control operation, the plug terminals must be

LU

ye
B
R
IC
A

maintained per these instructions with the recommended

N
TS

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 Figure 2
normal applications, plug maintenance should be
performed every two years, unless intermittent problems
arise with the plugs, requiring more immediate attention. 5. Reconnect plugs.
Warning: Do not use any other cleaners or lubricants
other than the ones specified. Reference

WARNING: Before conducting maintenance on the Cleaner Chemtronicsâ Pow-R-WasH CZ Contact

vehicle, jack up the drive wheels, disconnect the battery Cleaner
and discharge the capacitors. Consult the Operation and Lubricant Nyeâ Lubricants NYOGELâ 760G
Service Manual for your particular vehicle for details on
discharging the capacitors; this procedure differs GE Plug Lub Kit Contains both above products:
between SCR and Transistor controls. 328A1777G1

1. Disconnect plug from controller or mating plug.

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 19
Section 4.4 Controller Mounting Guidelines would prevent the control from sitting flush with the vehicle
mounting surface. Examine the base of the control to verify
In the design of the GE family of motor controls, that it is in good condition and free from damage or
performance assumptions were made based on heat contamination.
transfer between the control and the ambient environment.
The vehicle mounting surface acts as a heat sink, which Section 4.4.3 Vehicle Mounting Surface
increases the effective surface area for heat dissipation. If The quality of the vehicle mounting surface is critical for
this assumed heat transfer is not achieved during control the optimum heat transfer between the control and the
installation and operation, GE controllers will fall short of ambient environment. Conduction through the base of the
their anticipated performance. It should be noted that the control is the control’s only means of heat rejection. While
condition of the mounting surface, and the quality of the GE controls are highly efficient, a few percent of the
resulting interface between the control and the vehicle, can electrical energy will be converted into heat. As previously
significantly hinder heat transfer from the control. The mentioned, if this energy is not dissipated through the base
presence of contaminants, or of air voids created by of the control, a thermal protector will reduce the
surface inconsistencies in either the vehicle or the control, performance of the control until the temperature stabilizes.
degrade the control’s capacity for heat transfer. The
control’s performance is de-rated proportionally as its own For optimal heat transfer from control to vehicle, the
thermal sensors reduce its operation to protect it from flatness of the vehicle mounting surface should be
damage due to excessive heating. equivalent to the flatness of the control surface (0.005” per
linear inch). Use a straight edge or dial indicator to verify
Contained within the software of the GE controls are the mounting surface.
several diagnostic status codes related to controller
thermal performance. Failure to follow these mounting The biggest hindrance to heat transfer is the presence of
recommendations increases the likelihood of encountering rust, scale, weld splatter or paint on the vehicle mounting
these status codes, through no fault of the control itself, surface. If any of these items are noted, prepare the
thus voiding controller warranty for units returned solely surface per the following guidelines:
due to the presence of these status codes.
a) Clean the mounting surface with a rotary wire
Careful surface preparation, including adequate brush until the metal surface is exposed.
application of thermal compound, as detailed in the b) Using 80-100 grit emery paper, sand the
following paragraphs, must be completed during the surface until the metal shines.
installation of GE controls. There are many techniques for c) Flush the surface clean with an appropriate
applying thermal compound, and we have outlined one liquid de-greaser or parts cleaner.
approach below that has shown to apply a consistent
thickness of material. Section 4.4.4 Application of Thermal Compound
Due to the minute differences in the control mounting
Section 4.4.1 Necessary Tools surface and the vehicle mounting surface, small pockets of
GE recommends the use of the following components, or air will be created. These air pockets will add to the overall
equivalent substitutions, during the control installation thermal resistance of the interface.
process:
a) Thermal compound, (Dow Corning #340),
maintained per the manufacturer’s To avoid these air pockets and improve thermal
recommendations and free of contaminants conductivity, thermal compound must be applied between
b) 3/32” notched trowel, such as a Krusin the GE control base plate and the vehicle mounting surface.
adhesive spreader, model 00031 The function of this compound is to conform to surface
c) Calibrated torque wrench (0 – 15 ft-lbs) discrepancies, filling gaps and optimizing the metal-to-
metal contact of the control and the vehicle.
Section 4.4.2 The GE Control Mounting Surface
During the manufacture of the GE control, the surface
flatness is maintained at 0.005” per linear inch (not to a) Prepare the two mounting surfaces (control
exceed 0.025” per 10.0 inches). The surface finish of the GE and vehicle) as indicated above.
control has an Ra (average roughness) of 64 (microinches),
b) Using a triangular notched trowel of 3/32”
or better. This finish is consistent with cold rolled or
(.09” +/- .01), apply the grease to the vehicle
extruded aluminum.
mounting surface.
Care should always be taken in the handling and storage of c) Use straight, non-crossing strokes of the
controllers. The base of the control should be free from trowel to apply the compound.
nicks, bumps, protrusions or any other foreign object that
October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 20
d) Make multiple vertical passes until a uniform
consistency is achieved.

1 4

1 3

3 2
2

8 5

4 5

2 3
Krusin adhesive spreader model 00031
2 1

4 1

6 3
6 7

Proper sequence for use in tightening hardware during

control mounting

Section 4.4.6 Maintenance

If it is necessary to remove the control for service, careful
Vehicle surface after proper grease application
consideration must be given to removing the old thermal
compound from the control and mounting surface, prior to
Section 4.4.5 Mounting the GE Control
replacement of the unit. Never re-use thermal compound.
a) Place the control unit with desired orientation on
Use a putty knife or similar straight edge to carefully
mounting plate with mounting holes aligned.
remove all thermal compound residue without damaging
b) Move the control slightly in all directions to
either mounting surface. Flush the surfaces with a liquid
eliminate voids and enhance the distribution of the
de-greaser or parts cleaner and allow them to dry, before
thermal compound.
re-applying the thermal compound and mounting the
c) Insert the all of the mounting hardware (4, 6 or 8
control. Take care not to contaminate the surfaces with
bolts, M6 or M8, necessary for the mounting of the
hydraulic fluid or battery acid.
respective family of controls).
d) Tighten these bolts (as per sequence shown in
Section 4.5 General Troubleshooting Instructions
diagrams below) to half of the nominal torque
value (7.5lb-ft).
Trouble-shooting the SX family of controls should be quick
e) Lastly, tighten the bolts to the nominal torque
and easy when following the instructions outlined in the
value (15 lb-ft), following the same sequence.
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
Calibrated torque wrench for hardware installation 199) are pump control status codes.

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 21
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.

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 22
Section 4.6 Traction Control Codes

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Segments do not illuminate on the No input voltage to the control card or the display unit.
NONE Dash Display and/or the Handset.
MEMORY RECALL
NO CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Display screen on Dash Display and/or Handset
Circuits valid is blank. KEY
for FU3 SWITCH
POSSIBLE CAUSE
Traction Positive or negative control voltage is not
Controller present. FU5
1A
· Insure that the key switch is closed and
voltage is present between P1 & battery L
negative (Power Terminal “NEG”). Also check +

for voltage between P2 and control negative.

Open circuit between control card AND the Dash

Display or Handset. -

· Check for an open circuit or loose connection P1 P18 P17 P2

NEG
going from the control and the Dash Display or
Handset.

Defective Dash Display or Handset.

· Replace Dash Display or Handset.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
No seat switch or deadman switch This status code will be displayed when P6 is less
-01 input (no voltage to P6). than 50% battery volts.
MEMORY RECALL
NO CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Circuits valid Control will not operate. KEY
for FU3 SWITCH
POSSIBLE CAUSE
Traction Mis-adjusted or defective seat or deadman REVERSE SW.
FORWARD SW.
START SW.
SEAT SW.

Controller switch. FU5

1A
· Check to see that the seat switch closes
properly.
SP
+

Open circuit between battery positive and P6. L

· Check for loose connections or broken wires:
- Between the seat switch and P6
- Between the key switch and the battery -

P1 P18 P17 P2 P6 P3 P4 P5
positive side of the seat switch.
- Between the seat switch and P2. NEG

· On vehicles without a seat/deadman switch,

check for a loose connection or broken wire
from P2 and/or P6.

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 23

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Forward directional switch is closed on This status code will be displayed when P4 is greater
-02 initial power up. than 60% of battery voltage at initial key switch on.

MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Control will not operate because of Static Return
Circuits valid to Off (SRO) lock out. KEY
for FU3 SWITCH
POSSIBLE CAUSE
Traction Forward directional switch is closed on initial

REVERSE SW.
FORWARD SW.
START SW.
SEAT SW.
Controller start up (i.e. closure of battery, key switch or FU5
1A
seat switch).
· Return directional switch lever to neutral and
then return lever to forward position. +
SP
L
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 P1 P18 P17 P2 P6 P3 P4 P5

returned to neutral. NEG

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.

Defective control.
· Replace the controller unit.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Reverse directional switch is closed on This status code will be displayed when P5 is greater
-03 initial power up. than 60% of battery voltage at initial key switch on.

MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Control will not operate because of Static Return
Circuits valid to Off (SRO) lock out. KEY
for FU3 SWITCH
POSSIBLE CAUSE
Traction Reverse directional switch is closed on initial
REVERSE SW.
FORWARD SW.
START SW.
SEAT SW.

Controller start up (i.e. closure of battery, key switch or FU5

1A
seat/deadman switch).
· Return directional switch lever to neutral and
then return lever to reverse position. +
SP
L
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 P1 P18 P17 P2 P6 P3 P4 P5

returned to neutral. NEG

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. Defective control. Replace
the controller unit.

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 24

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Start switch fails to close. This status code will be displayed when P7 is less
-05 than 2.5 volts and P3 is less than 60% of battery volts.

MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Circuits valid Control will not operate.
KEY
for POSSIBLE CAUSE
FU3 SWITCH

Traction Defective start switch circuit.

REVERSE SW.
FORWARD SW.
START SW.
SEAT SW.
Controller · Check start switch to insure closure FU5
1A

when accelerator is depressed.

· Check for open circuit or loose SP

NEG
+

connections in wiring from brake L

switch to start switch and from P3 to

start switch. -

P1 P18 P17 P2 P6 P3 P4 P5
P9 P7
Defective accelerator switch. NEG
· Check accelerator switch
potentiometer for proper operation
and ohmic value. ACC POT

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Accelerator depressed with no This status code will be displayed when P4 and P5
-06 direction selected. are less than 60% of battery volts, and P7 is less than
2.5 volts.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Control will not operate.
Circuits valid FU3
KEY
SWITCH
for POSSIBLE CAUSE

REVERSE SW.
Traction Accelerator pedal is depressed before
FORWARD SW.
START SW.
SEAT SW.

closing forward or reverse directional 1A

FU5
Controller switch.
· Status code will disappear when
SP
NEG

directional switch is closed or when +

L
accelerator pedal is released.

Defective directional switch -

· Check forward or reverse switch to insure P1 P18 P17 P2 P6 P3 P4 P5

P9 P7
closure when direction is selected. NEG

Open circuit between directional switch(es)

and battery positive or between directional
ACC POT
switch(es) and P4 or P5.
· Check all control wires and connections
shown in Trouble Shooting Diagram.

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 25

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Accelerator input voltage too high This status code will be displayed when the
-07 during run mode. accelerator input voltage at P7 is higher than 4.2
volts.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Control will not operate when accelerator pedal
Circuits valid is depressed or status code -07 is displayed
for then disappears when the vehicle starts to
accelerate.
Traction POSSIBLE CAUSE
Controller Accelerator input mis-adjusted or defective. P9 P7
· Input voltage at P7 should be less than 4.2
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 NEGATIVE
depressed.

Open circuit between battery negative and P7 in

accelerator input circuit.
· Check for broken wires or loose connections ACC POT
or open potentiometer / voltage supply.

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 4.2
volts for solid state type accelerator input.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Accelerator input voltage too low on This status code will be displayed when the
-08 power up after initial key switch accelerator input voltage at P7 is less than 3.0 volts,
closure. and any of the following connections are opened and
closed: battery plug or key switch.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Control will not operate.
Circuits valid
for POSSIBLE CAUSE
Accelerator input mis-adjusted or defective.
Traction · Input voltage at P7 should be more than 3.0
Controller volts. Adjust or replace accelerator unit to P9 P7
insure that the voltage at P7 is more than 3.0
volts before depressing pedal.

Short circuit between battery negative and P7 in NEGATIVE

accelerator input circuit.
· Disconnect wire from P7. Check for short
circuit from wire to battery negative.

Defective Control ACC POT

· Disconnect wire from P7. Measure voltage
from P7 to negative. Voltage should be greater
than 4.5 volts, if not, replace control.

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 26

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Both the forward and reverse This status code will be displayed when P4 and P5
-09 directional switches are closed at the are greater than 60% of battery volts at the same
same time. time.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Control will not operate.
Circuits valid KEY
for POSSIBLE CAUSE FU3 SWITCH

Traction Forward or reverse directional switch

REVERSE SW.
FORWARD SW.
START SW.
SEAT SW.
welded closed or mis-adjusted to be held
Controller closed. FU5
1A

· Replace or adjust directional switches to

insure that they open when directional +
SP
switch is returned to neutral. L

Short circuit between battery positive and

P4 and/or P5. -

P1 P18 P17 P2 P6 P3 P4 P5
· Disconnect wires from P4 and P5 and
check wire for short circuit to positive NEG

side of directional switch.

Defective Control
· Disconnect wires and measure voltage at
P4 and P5. Voltage should be less than
60% of battery volts.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Start switch closed on power up after This status code will be displayed when P3 is greater
-11 initial key switch closure. than 60% of battery voltage when the key switch is
closed.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Control will not operate. KEY
Circuits valid FU3 SWITCH

for POSSIBLE CAUSE REVERSE SW.

FORWARD SW.
START SW.

Start switch input mis-adjusted or defective.

SEAT SW.

Traction · Input voltage at P3 should be less than 60% of FU5

1A

Controller battery volts at key switch closing. Adjust or

replace accelerator unit to insure that the
SP
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. -

P1 P18 P17 P2 P6 P3 P4 P5
· Disconnect wire from P3. Check for short
circuit from this wire to battery positive. NEG

Defective control.
· Disconnect wire from P3. Measure voltage
from P3 to negative. Voltage should be zero,
if not, replace control.

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 27

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Battery voltage is too low or control This status code will be displayed when the battery
-15 card is mis-adjusted. volts are less than 1.95 volts per cell at initial key
switch on. See table below.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM FU5
Control will not operate.
Circuits valid MINIMUM
NOMINAL
for POSSIBLE CAUSE BATTERY
LIMIT VOLTS
AT 1.95 VDC
Traction Discharged battery VOLTAGE
PER CELL
· Check battery for proper open circuit
Controller voltage as shown in “Trouble Shooting
24 23.4
36 35.1
Diagram”, charge battery, if required. 48 46.8
72 70.2
Defective battery + P1
80 78.0
· Check each battery cell for proper
voltage (greater than 1.95 volts at cell).
-
Replace or repair battery.
NEG

Incorrect control card adjustment.

· 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 DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Battery voltage is too high or control This status code will be displayed when the battery
-16 card is mis-adjusted. volts are greater than 2.4 volts per cell at initial key
switch on. See table below.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM FU5
Control will not operate.
Circuits valid MAXIMUM
NOMINAL
for POSSIBLE CAUSE BATTERY
LIMIT VOLTS
AT 1.95 VDC
Traction Incorrect control card adjustment VOLTAGE
PER CELL
Check Function 15 for proper adjustment
Controller for battery being used. See Handset
24 28.8
36 43.2
instructions for details. Adjust to proper 48 57.6
setting. 72 86.4
+ P1
80 100.8
Battery over charged or incorrect battery
used.
· Check battery for proper open circuit -

voltage per table at right. If voltage is NEG

excessive, check battery charger for

proper output voltage.

Check “maximum” battery volts at P1 and

NEG.

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 28

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Motor field current is high on start up in This status code will be displayed when the current
-23 the reverse direction. draw in the motor field is too high at start up in the
reverse direction.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
FU3 KEY SWITCH *
Circuits valid Control will not operate. DIRECT SW.

SEAT SW.
*
*
ACCEL
for POSSIBLE CAUSE
1A START
SW.
FWD
REV
*
Traction Defective control. FU5 SP
L
Controller · Replace controller unit.
LINE
P18 P17 P2 P6 P3 P4 P5
P1 P7 P9 OSC CARD CONNECTIONS
ACCEL
START
FU1 SW. *
*
A1
+
F1 F1
POS A1

ARMATURE
CONTROL

FIELD
-* POWER
CONNECTION
NEG A2
*
F2 F2

A2

1A

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Motor field current is high on start up in This status code will be displayed when the current
-24 the forward direction. draw in the motor field is too high at start up in the
forward direction.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
FU3 KEY SWITCH *
Control will not operate. DIRECT SW.
Circuits valid
SEAT SW.

*
*
ACCEL
for POSSIBLE CAUSE
1A START
SW.
FWD
REV
*
Traction Confirm that motor field stud is not FU5 SP
L
Controller shorted to hydraulic pump hose/tube
assembly. LINE
P18 P17 P2 P6 P3 P4 P5
P1 P7 P9 OSC CARD CONNECTIONS
Defective control. ACCEL
·Replace controller unit. FU1
START
SW. *
*
A1
+
F1 F1
POS A1
ARMATURE

CONTROL
FIELD

-* POWER
CONNECTION
NEG A2
*
F2 F2

A2

1A

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 29

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Control’s power supply is less than 10 This status code will be displayed when the control’s
-27 Volts DC. power supply is less than 10 volts.

MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
KEY
Circuits valid Line contactor closes and opens, then FU3 SWITCH
can only be closed by opening and
for closing the key switch.
Traction FU5
1A

Controller POSSIBLE CAUSE

L
Discharged Battery
· Check battery to insure proper state
+

of charge. Voltage may be dropping

below 10 Volts DC under load. -

P1 P18 P17 P2
NEG
Loose connection at P1.
· Insure that the wire connection at P1
is tight.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Motor field current has remained too This status code will be displayed when the current in the
-28 high during the run mode. motor field is sustained above a preset limit for longer
than 70 seconds.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
Circuits valid Control will not operate.
for POSSIBLE CAUSE THE PRESENCE OF THIS STATUS CODE IS
Traction Continued operation of vehicle in NOT NECESSARILY INDICATIVE OF A
Controller high motor current condition. CONTROL ISSUE. THIS STATUS CODE
· Operate vehicle at lower motor
current condition for 70
MAY INDICATE AN APPLICATION ISSUE.
seconds. DISPLAY OF THIS STATUS CODE SHOULD
NOT TRIGGER THE RETURN OF A
Function 7 is mis-adjusted to allow CONTROL FOR REPAIR OR
higher than normal motor field
REPLACEMENT
current.
· Adjust function per OEM
instructions.

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 30

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Open thermal protector (TP) or This status code will be displayed when the voltage at
-41 transistor over temperature. the thermal protector is too high.

MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
YES *
SYMPTOM
Circuits valid Reduced or no power to traction motor
in control range.
for THE PRESENCE OF THIS STATUS CODE
Traction POSSIBLE CAUSE IS NOT NECESSARILY INDICATIVE OF A
Controller Control is in thermal cut-back. CONTROL ISSUE. THIS STATUS CODE
· Allow control to cool, status code
should disappear.
MAY INDICATE AN APPLICATION ISSUE.
· Insufficient heat transfer may be DISPLAY OF THIS STATUS CODE
occurring between control and SHOULD NOT TRIGGER THE RETURN OF
mounting surface. Refer to control A CONTROL FOR REPAIR OR
mounting guidelines in section 4.4 of REPLACEMENT.
this manual.

* First status code displayed

immediately, additional status codes
displayed in 20 hour intervals.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Motor armature offset voltage is too This status code will be displayed when the voltage at
-42 high. the current sensor input is greater than 2.6 volts with
no current flowing in the motor circuit.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
FU3 KEY SWITCH *
Circuits valid Control will not operate. DIRECT SW.
SEAT SW.

*
*
ACCEL
for POSSIBLE CAUSE
1A START
SW.
FWD
REV
*
Traction Defective control. FU5 SP
L
Controller · Replace controller unit.
LINE
P18 P17 P2 P6 P3 P4 P5
P1 P7 P9 OSC CARD CONNECTIONS
ACCEL
START
FU1 SW. *
*
A1
+
F1 F1
POS A1
ARMATURE

CONTROL
FIELD

-* POWER
CONNECTION
NEG A2
*
F2 F2

A2

1A

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 31

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Motor armature offset voltage is too This status code will be displayed when the voltage at
-43 low. the current sensor input is less than 2.4 volts with no
current flowing in the motor circuit.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
FU3 KEY SWITCH *
Control will not operate. DIRECT SW.
Circuits valid

SEAT SW.
*
*
ACCEL
for POSSIBLE CAUSE
1A START
SW.
FWD
REV
*
Traction Defective control. FU5 SP
L
Controller · Replace controller unit.
LINE
P18 P17 P2 P6 P3 P4 P5
P1 P7 P9 OSC CARD CONNECTIONS
ACCEL
START
FU1 SW. *
*
A1
+
F1 F1
POS A1

ARMATURE
CONTROL

FIELD
-* POWER
CONNECTION
NEG A2
*
F2 F2

A2

1A

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Armature transistor did not turn off This status code will be displayed when, during
-44 properly. control operation, the armature transistor fails to turn
off. This will result in a PMT condition.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
FU3 KEY SWITCH *
Circuits valid Line contactor closes and opens, then DIRECT SW.
SEAT SW.

*
*
can only be closed by opening and ACCEL
for closing the key switch.
1A START
SW.
FWD
REV
*
Traction FU5 SP
L
Controller POSSIBLE CAUSE
Defective control. LINE
· Replace controller unit. P18 P17 P2 P6 P3 P4 P5
P1 P7 P9 OSC CARD CONNECTIONS
ACCEL
START
FU1 SW. *
*
A1
+
F1 F1
POS A1
ARMATURE

CONTROL
FIELD

-* POWER
CONNECTION
NEG A2
*
F2 F2

A2

1A

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 32

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Armature transistor did not turn on This status code will be displayed when, during
-45 properly. control operation, the armature transistor fails to turn
on properly. This will result in a PMT condition.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
FU3 KEY SWITCH *
Circuits valid Line contactor closes and opens, then DIRECT SW.

SEAT SW.
*
*
can only be closed by opening and ACCEL
for closing the key switch.
1A START
SW.
FWD
REV
*
Traction FU5 SP
L
Controller POSSIBLE CAUSE
Possible cable routing issue with the LINE
P18 P17 P2 P6 P3 P4 P5
power cables to the 1A contactor P1 P7 P9 OSC CARD CONNECTIONS
routed too closely to the control ACCEL
· Refer to OEM guidelines for cable FU1
START
SW. *
*
placement near 1A contactor. A1
+
F1 F1
POS A1

ARMATURE
CONTROL

FIELD
-* POWER
CONNECTION
NEG A2
*
F2 F2

A2

1A

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
“Look Ahead” test for A2 volts less This status code will be displayed when the voltage at
-46 than 12% of battery volts. A2 is less than 12% of battery volts.

MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
FU3 KEY SWITCH *
Circuits valid Line contactor will not pick up. DIRECT SW.
SEAT SW.

*
*
ACCEL
for 1A START
SW.
FWD
REV
*
Traction POSSIBLE CAUSE FU5 SP
L
Controller Check for short circuit from the motor
armature to the frame of the vehicle. LINE
P18 P17 P2 P6 P3 P4 P5
P1 P7 P9 OSC CARD CONNECTIONS
Possible 1A contactor tips welded ACCEL
·Refer to OEM service bulletin FU1
START
SW. *
*
regarding 1A tip welding on this A1
+
platform. F1 F1
POS A1
ARMATURE

CONTROL
FIELD

-* POWER
CONNECTION
NEG A2
*
F2 F2

A2

1A

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 33

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Motor field current is too low during the This status code will be displayed when the current draw in
-49 run mode. the motor field is less than 3.1 amps, while the armature
current is greater than 100A for 2.0 seconds during run
mode.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
FU3 KEY SWITCH *
Circuits valid Control will only operate for a second DIRECT SW.

SEAT SW.
*
*
or two before shutting down. ACCEL
for 1A START
SW.
FWD
REV
*
Traction POSSIBLE CAUSE FU5 SP
L
Controller If the fault code is intermittent, verify
that the accelerator pot is adjusted LINE
P18 P17 P2 P6 P3 P4 P5
correctly. P1 P7 P9 OSC CARD CONNECTIONS
ACCEL
START
SW. *
Check for open motor field coils or * FU1
A1
loose or intermittent field connections, +
or open F1 or F2 connections. F1 F1
POS A1

ARMATURE
CONTROL

FIELD
-* POWER
CONNECTION
NEG A2
*
F2 F2

A2

1A

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Capacitor volts are low before the line This status code will be displayed during “key on” when the
-51 contactor closes. capacitor volts is less than 85% of battery volts at initial key
switch on.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
FU3 KEY SWITCH *
Circuits valid Line contactor does not close when DIRECT SW.
SEAT SW.

*
*
capacitor does not precharge. ACCEL
for 1A START
SW.
FWD
REV
*
Traction POSSIBLE CAUSE FU5 SP
L
Controller Defective control fuse (FU5).
· Check control fuse for open circuit. LINE
P18 P17 P2 P6 P3 P4 P5
Replace fuse, if necessary. P1 P7 P9 OSC CARD CONNECTIONS
Loose connector at P1. ACCEL

· Verify connection at P1. * FU1

START
SW. *
A1
Verify that no external load has been +
added to the low side of the line F1 F1
POS A1
ARMATURE

contactor. CONTROL
FIELD

-* POWER
CONNECTION
Note: Repeated charging/discharging NEG A2
*
F2 F2
of the capacitors during
troubleshooting may cause this status A2

code to appear.
1A

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 34

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Controller “motor current sensor” This status code will be displayed when the voltage
-57 input too low during running. input from the current sensor is too low (line contactor
bounces open twice) during running.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
FU3 KEY SWITCH *
Circuits valid Control will not operate. DIRECT SW.

SEAT SW.
*
*
ACCEL
for POSSIBLE CAUSE
1A START
SW.
FWD
REV
*
Traction Defective control. FU5 SP
L
Controller · Replace controller unit.
LINE
P18 P17 P2 P6 P3 P4 P5
P1 P7 P9 OSC CARD CONNECTIONS
ACCEL
START
FU1 SW. *
*
A1
+
F1 F1
POS A1

ARMATURE
CONTROL

FIELD
-* POWER
CONNECTION
NEG A2
*
F2 F2

A2

1A

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
The line driver input (P2-17) is less This status code will be displayed when the control
-64 than 12% of battery volts detects that the line driver input (P2-17) is less than
12% battery volts when the key switch is turned on.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
FU3 KEY SWITCH *
Circuits valid Control will not operate. DIRECT SW.
SEAT SW.

*
*
ACCEL
for POSSIBLE CAUSE
1A START
SW.
FWD
REV
*
Traction -Open wire connection to Pin 17 FU5 SP
L
Controller - Shorted line Driver transistor
LINE
P18 P17 P2 P6 P3 P4 P5
Defective control. P1 P7 P9 OSC CARD CONNECTIONS
· Replace controller unit. ACCEL
START
FU1 SW. *
*
A1
+
F1 F1
POS A1
ARMATURE

CONTROL
FIELD

-* POWER
CONNECTION
NEG A2
*
F2 F2

A2

1A

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 35

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
The line coil current is too high during This status code will be displayed when the current
-65 the run mode limit in the line coil is exceeded during the run mode.
The line contactor will drop out and the accelerator
will have to be recycled to reset the control.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
FU3 KEY SWITCH *
Circuits valid Control will not operate. DIRECT SW.

SEAT SW.
*
*
ACCEL
for POSSIBLE CAUSE
1A START
SW.
FWD
REV
*
Traction FU5 SP
L
Controller - Shorted line contactor coil
- Short between wires connected to LINE
P18 P17 P2 P6 P3 P4 P5
line coil (wires #10 and 24) P1 P7 P9 OSC CARD CONNECTIONS
ACCEL
START
FU1 SW. *
*
A1
+
F1 F1
POS A1

ARMATURE
CONTROL

FIELD
-* POWER
CONNECTION
NEG A2
*
F2 F2

A2

1A

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
The field current exceeds the current limit of This status code will be displayed when the field
-66 the field transistor. transistor exceeds its specific current limit.
The line contactor will drop out and the accelerator
will have to be recycled to restart the control.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
FU3 KEY SWITCH *
Circuits valid Control will not operate or is sluggish on start DIRECT SW.
SEAT SW.

*
*
up. Line contactor opens ACCEL
for 1A START
SW.
FWD
REV
*
Traction POSSIBLE CAUSES
FU5 SP
L

Controller Blown FU1 fuse.

LINE
P18 P17 P2 P6 P3 P4 P5
Shorted field F1 to F2 P1 P7 P9 OSC CARD CONNECTIONS

· F1 or F2 terminals shorted to battery positive ACCEL

START
(B+) or to battery negative (B-) * FU1
A1
SW. *

+
Binding line contactor POS A1
F1 F1
ARMATURE

· Visually inspect tips, clean them with solvent. CONTROL

FIELD

-* POWER

· Confirm that contactor includes G248 coil. CONNECTION

NEG A2
*
F2 F2

Noise A2
· Missing or damaged horn suppressor
Confirm that all inductive loads/accessories 1A

are suppressed.

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 36

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
The armature current exceeds the This status code will be displayed when the armature
-67 armature transistor limit. transistor exceeds its specific current limit. The
control is reset by recycling the accelerator.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
FU3 KEY SWITCH *
Circuits valid Control will not operate. DIRECT SW.

SEAT SW.
*
*
ACCEL
for POSSIBLE CAUSE
1A START
SW.
FWD
REV
*
Traction Shorted motor armature A1 to A2 FU5 SP
L
Controller
Power cables may be shorted to each LINE
P18 P17 P2 P6 P3 P4 P5
other (Measure at control terminals) P1 P7 P9 OSC CARD CONNECTIONS
· A1 to A2 terminals may be shorted to ACCEL
START
battery positive or negative * FU1 SW. *
A1
+
Noise F1 F1
POS A1
· Missing or damaged horn suppressor

ARMATURE
CONTROL

FIELD
Confirm that all inductive -* POWER
CONNECTION
NEG A2
loads/accessories are suppressed. *
F2 F2

A2

1A

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
The power steering coil current is too This status code will be displayed when the current in
-69 high during the run mode. the power steering driver circuit exceeds current limit
during the run mode. The control is reset by recycling
the accelerator.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
FU3 KEY SWITCH *
Circuits valid Control will not operate. DIRECT SW.
SEAT SW.

*
*
ACCEL
for POSSIBLE CAUSE
1A START
SW.
FWD
REV
*
Traction · Shorted power steering control coil
FU5 SP
L
Controller
· Short between wires connecting to
LINE
the power steering coil (wire # 10 P18 P17 P2 P6 P3 P4 P5
and 60) P1 P7 P9 OSC CARD CONNECTIONS
ACCEL
START
FU1 SW. *
*
A1
+
F1 F1
POS A1
ARMATURE

CONTROL
FIELD

-* POWER
CONNECTION
NEG A2
*
F2 F2

A2

1A

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 37

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Capacitor (1C) voltage too high. This status code will be displayed when the
-76 voltage on the capacitor goes above limit voltage*
during the regenerative braking cycle.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
FU3 KEY SWITCH *
Circuits valid Line contactor opens and closes, then DIRECT SW.

SEAT SW.
*
*
opens and can only close by opening and ACCEL
for closing the key switch.
1A START
SW.
FWD
REV
*
Traction FU5 SP
L
Controller POSSIBLE CAUSE
· Unplugging the battery connector during LINE
P18 P17 P2 P6 P3 P4 P5
regenerative braking. P1 P7 P9 OSC CARD CONNECTIONS
· Line contactor bouncing open during ACCEL
START
regen. * FU1 SW. *
· Main power fuse opening during regen. +
A1

· Intermittent battery plug connection. POS A1

F1 F1

ARMATURE
· Missing or damaged horn suppressor. CONTROL

FIELD
-* POWER
CONNECTION
NEG A2
* Limit Voltage: *
F2 F2
Limit Batt.
50V 36V A2

70V 48V
1A
96V 72/80V

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Motor current is detected during This status code will be displayed when motoring
-77 regenerative braking. current is detected during the regenerative braking
cycle.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
FU3 KEY SWITCH *
Circuits valid Line contactor closes then opens and DIRECT SW.
SEAT SW.

*
*
can only close by opening and closing ACCEL
for the key switch.
1A START
SW.
FWD
REV
*
Traction FU5 SP
L
Controller POSSIBLE CAUSE
Defective control. LINE
· Replace controller unit P18 P17 P2 P6 P3 P4 P5
P1 P7 P9 OSC CARD CONNECTIONS
ACCEL
START
FU1 SW. *
*
A1
+
F1 F1
POS A1
ARMATURE

CONTROL
FIELD

-* POWER
CONNECTION
NEG A2
*
F2 F2

A2

1A

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 38

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
If the armature current is greater than 1100 This status code will be displayed when the armature current
-82 amps in 1A mode; or greater than 730 amps for
longer than 3.5 seconds in control mode, the
exceeds 1100 amps in the 1A mode, or 730 amps for 3.5 sec and
the accelerator pedal is calling for maximum performance in the
armature motoring current will be turned off. control mode.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Circuits valid The Control will not operate, and can
only be reset by cycling the
for accelerator. THE PRESENCE OF THIS STATUS CODE
Traction IS NOT NECESSARILY INDICATIVE OF A
Controller POSSIBLE CAUSE: CONTROL ISSUE. IF FUNCTION 16 IS
· Continued operation of vehicle in
high motor current condition NOT MIS-ADJUSTED, THE STATUS CODE
· Operating control at stall motor INDICATES AN APPLICATION ISSUE
current for more than 3.5 seconds. WHERE A MOTOR IS BEING STALLED,
· Function 16 is incorrectly adjusted ETC. DISPLAY OF THIS STATUS CODE
for control % on time.
- Adjust function per OEM
SHOULD NOT TRIGGER THE RETURN OF
instructions A CONTROL FOR REPAIR OR
REPLACEMENT.

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 39
Section 4.7 TMM Codes
TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
STATUS CODE
Traction motor temperature has This status code will be displayed when the voltage at
-90 exceeded maximum temperature limit. the respective terminal of the TMM or Pump Logic
Card is at zero volts.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
YES *
SYMPTOM
Circuits valid Status code flashes “on and off”.
for POSSIBLE CAUSE
Traction Traction motor overheating.
Motor
Temperature Plug P16 (pump) is shorted to battery
negative.
P16 WHEN SR Series PUMP
Defective input switch (shorted). CONTROL IS USED

Defective TMM module.

Defective pump controller. USER SW

* First status code is displayed NEG

immediately, additional status codes SC90
are displayed in 20 hour intervals.

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Pump motor temperature has This status code will be displayed when the voltage at
-91 exceeded maximum temperature limit. the respective terminal of the TMM or Pump Logic
Card is at zero volts.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
YES *
SYMPTOM
Circuits valid Status code flashes “on and off”.
for POSSIBLE CAUSE
Traction Pump motor overheating.
Motor
Temperature Plug P11 (pump) is shorted to battery
negative.
P11 WHEN SR Series PUMP
Defective input switch (shorted). CONTROL IS USED

Defective TMM module

Defective pump controller. USER SW

* First status code is displayed NEG

immediately, additional status codes SC91
are displayed in 20 hour intervals.

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 40

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Steering pump motor brush wear This status code will be displayed when the voltage at
-93 indicator has detected worn brush. the respective terminal of the TMM or Pump Logic
Card is at battery volts.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
YES *
SYMPTOM
Circuits valid Status code flashes “on and off”.
for POSSIBLE CAUSE
Steer Steering motor brushes are worn.
Pump
Motor Plug P3 (pump) is shorted to positive.
Brush Wear
Defective input switch (shorted). P3
Indicator WHEN SR Series PUMP
CONTROL IS USED

Defective TMM controller.

Defective pump controller.

USER SW
* First status code is displayed
immediately, additional status codes POS
are displayed in 20 hour intervals. SC93

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Steering pump motor brush wear This status code will be displayed when the voltage at
-93 indicator has detected worn brush. the respective terminal of the TMM or Pump Logic
Card is at battery volts.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
YES *
SYMPTOM
Circuits valid Status code flashes “on and off”.
for POSSIBLE CAUSE
Steering Steering motor brushes are worn.
Pump
Motor Plug P4 (pump) is shorted to positive.
Brush Wear
Defective input switch (shorted). P4
Indicator WHEN SR Series PUMP
CONTROL IS USED

Defective TMM module.

Defective pump controller.

USER SW
* First status code is displayed
immediately, additional status codes POS
are displayed in 20 hour intervals. SC93A

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 41

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Traction motor brush wear indicator This status code will be displayed when the voltage at
-94 has detected worn brush. the respective terminal of the TMM or Pump Logic
Card is at battery volts.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
YES *
SYMPTOM
Circuits valid Status code flashes “on and off”.
for POSSIBLE CAUSE
Traction Traction motor brushes are worn.
Motor
Brush Wear Plug P5 (pump) is shorted to positive.
P5 WHEN SR Series PUMP
Indicator CONTROL IS USED
Defective input switch (shorted).

Defective TMM module.

USER SW
Defective pump controller.
POS
* First status code is displayed
immediately, additional status codes
are displayed in 20 hour intervals. SC94

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Traction motor brush wear indicator This status code will be displayed when the voltage at
-94 had detected worn brush. the respective terminal of the TMM or Pump Logic
Card is at zero volts.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
YES *
SYMPTOM
Circuits valid Status code flashes “on and off”.
for POSSIBLE CAUSE
Traction Traction motor brushes are worn.
Motor
Brush Wear Plug P6 (pump) is shorted to positive.
P6 WHEN SR Series PUMP
CONTROL IS USED
Defective input switch (shorted).

Defective TMM module.

USER SW
Defective pump controller.
POS
* First status code is displayed
immediately, additional status codes
are displayed in 20 hour intervals. SC94A

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 42

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Pump motor brush wear indicator has This status code will be displayed when the voltage at
-95 detected worn brush. the respective terminal of the TMM or Pump Logic
Card is at battery volts.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
YES *
SYMPTOM
Status code flashes “on and off”.
Circuits valid
for POSSIBLE CAUSE
Pump motor brushes are worn.
Pump
Motor Plug P8 (pump) is shorted to positive.

Brush Wear Defective input switch (shorted). P8 WHEN SR Series PUMP

Indicator CONTROL IS USED
Defective TMM module.

Defective pump controller

* First status code is displayed immediately,

additional status codes are displayed in 20 hour USER SW

intervals.
POS

SC95

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Pump motor brush wear indicator has This status code will be displayed when the voltage at
-95 detected worn brush. the respective terminal of the TMM or Pump Logic
Card is at battery volts.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
YES *
SYMPTOM
Status code flashes “on and off”.
Circuits valid
for POSSIBLE CAUSE
Pump motor brushes are worn.
Pump
Motor Plug P9 (pump) is shorted to positive.

Brush Wear Defective input switch (shorted). P9 WHEN SR Series PUMP

Indicator CONTROL IS USED
Defective TMM module.

Defective pump controller.

* First status code is displayed immediately,

additional status codes are displayed in 20 hour USER SW

intervals.
POS

SC95A

October 2002
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 43

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Maintenance alert and speed limit. This status code will be displayed when the “normal”
-99 hour meter exceeds the “maintenance alert hours”
setting for the vehicle.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO *
SYMPTOM
Status code is displayed for 4 seconds when the
Circuits valid key switch is first turned on, and/or the vehicle
for may run at a reduced speed.
NO DIAGRAM
Traction CUSTOMER SELECTED SETTING WITH THE
Controller HANDSET:
User defined status code is displayed when the
normal hour meter reading exceeds the
programmed “maintenance alert hours” setting USER SHOULD PERFORM THE DESIRED
selected by the user
· Maintenance Code Hour Meter, Functions 19 MAINTENANCE FUNCTION
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. Re-set maintenance alert hour meter
after maintenance is performed.

* First status code is displayed immediately,

additional status codes are displayed in 20 hour
intervals.

October 2002
DIAGNOSTIC STATUS CODES
TRANSISTOR PUMP CONTROL Page 44
Section 4.8 Pump Control Codes
PUMP DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
STATUS CODE
“Card Type” selection is invalid. This status code will be displayed when the card type
-117 selection value is set to an invalid number.

MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Circuits valid Control will not operate.
for NO
POSSIBLE CAUSE
Pump
Controller
Invalid card type selection.
· Review function 17 in the Handset
GRAPHIC
Instruction sheets. Adjust and set
card type value as instructed by OEM
FOR THIS
service manual.
STATUS CODE
Verify that the correct logic card
catalog number is installed in the
controller.

PUMP DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Control logic card power supply is less This status code is displayed when the logic card
-127 than 10 VDC. power supply is less than 10 volts.
MEMORY RECALL
YES CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM FU3 KEY SWITCH

Circuits valid Control will not operate.
for FU2

Pump POSSIBLE CAUSE

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
ARMATURE FIELD

· Replace control.
POS A1
-
POWER CONNECTIONS
NEG A2

October 2002
DIAGNOSTIC STATUS CODES
TRANSISTOR PUMP CONTROL Page 45

PUMP DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Armature current is too high during the Status code displayed when the current in the
-128 lift mode. armature circuit is sustained above 300A for 70 sec.
MEMORY RECALL
YES CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
FU3 KEY SWITCH
SYMPTOM
Circuits valid Control will not operate.
for FU2

Pump POSSIBLE CAUSE

Continued operation of vehicle in high
Controller motor current condition.
· Operate vehicle at lower motor current LINE FU1
condition for 70 seconds.
P1 P2

ARMATURE FIELD
POS A1
-
POWER CONNECTIONS
NEG A2

PUMP DESCRIPTION OF CAUSE OF STATUS INDICATION

STATUS CODE STATUS
Open thermal protector (TP1) or This status code is displayed when the voltage at the thermal
-141 transistor is over temperature. protector is greater than 0.8 volts.
MEMORY RECALL
YES * CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
FU3 KEY SWITCH
SYMPTOM TO TRACTION
Circuits valid Reduced or no power to pump motor in FU6 P10 - BDI

for control range. PY7

Pump POSSIBLE CAUSE

P1 P2 P3 PY12
P21 P19 P12 PY10
Controller PY11
Control is in thermal cut-back.
SPEED LIMIT 2
SPEED LIMIT 3

SPEED LIMIT 1

· Allow control to cool, status code

should disappear.
LINE FU1

* First status code is displayed

immediately, additional status codes are
displayed in 20 hour intervals.

+
ARMATURE FIELD

POS A1
- POWER
CONNECTIONS TO
TRACTION
NEG A2
CARD

October 2002
DIAGNOSTIC STATUS CODES
TRANSISTOR PUMP CONTROL Page 46

PUMP DESCRIPTION OF CAUSE OF STATUS INDICATION

STATUS CODE STATUS
Pump Controller “motor current This status code is displayed when the voltage at the
-142 sensor” input is missing. current sensor is greater than 0.1 volts with no current
flowing in the motor circuit.
MEMORY RECALL
NO CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
FU3 KEY SWITCH
TO TRACTION
Circuits valid SYMPTOM FU6 P10 - BDI
No power to pump motor in
for control range.
PY7

Pump P1 P2 P3 PY12
P21 P19 P12 PY10
Controller POSSIBLE CAUSE PY11

SPEED LIMIT 2
Control is defective.

SPEED LIMIT 3

SPEED LIMIT 1
· Replace controller unit.
LINE FU1

ARMATURE FIELD
POS A1
- POWER
CONNECTIONS TO
TRACTION
NEG A2
CARD

PUMP DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Pump Controller “motor current This status code is displayed when the voltage at the
-143 sensor” input is too low. current sensor is greater than 0.1 volts with no current
flowing in the motor circuit.
MEMORY RECALL
NO CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
FU3 KEY SWITCH
SYMPTOM TO TRACTION
Circuits valid No power to pump motor in
FU6 P10 - BDI

for control range. PY7

Pump P1 P2 P3 PY12
P21 P19 P12 PY10
Controller POSSIBLE CAUSE PY11

Control is defective.
SPEED LIMIT 2
SPEED LIMIT 3

SPEED LIMIT 1

· Replace controller unit.

LINE FU1

+
ARMATURE FIELD

POS A1
- POWER
CONNECTIONS TO
TRACTION
NEG A2
CARD

October 2002
DIAGNOSTIC STATUS CODES
TRANSISTOR PUMP CONTROL Page 47

PUMP DESCRIPTION OF CAUSE OF STATUS INDICATION

STATUS CODE STATUS
Power Transistor (Q1) did not This status code is displayed when, during pump control
-144 turn off properly. operation, the transistor fails to turn off. This will result in a
PMT condition.
MEMORY RECALL
YES CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
FU3 KEY SWITCH
SYMPTOM TO TRACTION
Circuits valid With no pump contactor, control
FU6 P10 - BDI

for may run continuously. PY7

Pump P1 P2 P3 PY12
P21 P19 P12 PY10
Controller POSSIBLE CAUSE PY11

Control is defective.

SPEED LIMIT 2
SPEED LIMIT 3

SPEED LIMIT 1
· Replace controller unit.
LINE FU1

ARMATURE FIELD
POS A1
- POWER
CONNECTIONS TO
TRACTION
NEG A2
CARD

PUMP DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Power Transistor (Q1) did not turn on This status code is displayed when during pump
-145 properly. control operation, the transistor fails to turn on.
MEMORY RECALL
YES CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
FU3 KEY SWITCH
SYMPTOM TO TRACTION
Circuits valid With no pump contactor, the
FU6 P10 - BDI

for control may run continuously. PY7

Pump P1 P2 P3 PY12
P21 P19 P12 PY10
Controller POSSIBLE CAUSE PY11

Control is defective.
SPEED LIMIT 2
SPEED LIMIT 3

SPEED LIMIT 1

· Replace controller unit.

LINE FU1

+
ARMATURE FIELD

POS A1
- POWER
CONNECTIONS TO
TRACTION
NEG A2
CARD

October 2002
DIAGNOSTIC STATUS CODES
TRANSISTOR PUMP CONTROL Page 48

PUMP DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
“Look Ahead” test for T2 volts This status code will be displayed when the voltage at T2 is
-146 less than 12% of battery volts. less than 12% of battery volts.
MEMORY RECALL
YES CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
FU3 KEY SWITCH
SYMPTOM TO TRACTION
Circuits valid Pump control will not operate.
FU6 P10 - BDI

for PY7

Pump POSSIBLE CAUSE P1 P2 P3 PY12

P21 P19 P12 PY10
Controller Check for short circuit from the PY11

motor armature to the frame of

SPEED LIMIT 2
SPEED LIMIT 3

SPEED LIMIT 1
the vehicle.
LINE FU1

Control is defective.
· Replace controller unit.

ARMATURE FIELD
POS A1
- POWER
CONNECTIONS TO
TRACTION
NEG A2
CARD

PUMP DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS
CODE
Capacitor volts are low after the line This status code will be displayed when the capacitor voltage
-150 contactor closes. is less than 85%of the battery voltage in the run mode.
MEMORY
RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM FU3 KEY SWITCH
Pump control will not operate. TO TRACTION
Circuits FU6 P10 - BDI

valid for POSSIBLE CAUSE PY7

Pump Defective line contactor. P1 P2 P3 PY12

P21 P19 P12 PY10
· Check for open line contactor power
Controller tips.
PY11
SPEED LIMIT 2
SPEED LIMIT 3

SPEED LIMIT 1

Check for loose or open connections in

LINE FU1
cables from battery positive to control
positive circuit.

Defective power fuse.

· Check power fuse for open circuit.
+
ARMATURE FIELD

No battery voltage at P1. POS A1

POWER
· Check for battery voltage at POS and -
CONNECTIONS TO
P1. NEG A2
TRACTION
· Check for loose connection at P1. CARD

October 2002
DIAGNOSTIC STATUS CODES
TRANSISTOR PUMP CONTROL Page 49

TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Capacitor volts are low before the line This status code will be displayed during “key on” when
-151 contactor closes. (Internal card the capacitor volts is less than 85% of battery volts at
function during precharge) initial key switch on.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM FU3 KEY SWITCH
TO TRACTION
Pump control will not operate.
Circuits valid FU6 P10 - BDI

for POSSIBLE CAUSE PY7

P1 P2 P3 PY12
Pump Defective control fuse. P21 P19 P12 PY10
· Check control fuse for open PY11
Controller

SPEED LIMIT 2
circuit, replace fuse, if necessary.

SPEED LIMIT 3

SPEED LIMIT 1
Defective control. LINE FU1
· Replace controller unit.

Note: Repeated
“charging/discharging” the
+
capacitors during troubleshooting

ARMATURE FIELD
POS A1
will cause status code 51. Also “do
- POWER
not” connect any loads to the low CONNECTIONS TO
side of the line contactor. NEG A2
TRACTION
CARD

PUMP DESCRIPTION OF CAUSE OF STATUS INDICATION

STATUS CODE STATUS
Controller “motor current This status code will be displayed when the voltage input to
-157 sensor” input voltage polarity motor current sensor is of the wrong polarity.
check.
MEMORY RECALL
NO CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM FU3 KEY SWITCH
TO TRACTION
Circuits valid Pump control will not operate. FU6 P10 - BDI

for POSSIBLE CAUSE

PY7

Pump Control is defective.

P1 P2 P3 PY12
P21 P19 P12 PY10
Controller · Replace controller unit. PY11
SPEED LIMIT 2
SPEED LIMIT 3

SPEED LIMIT 1

LINE FU1

+
ARMATURE FIELD

POS A1
- POWER
CONNECTIONS TO
TRACTION
NEG A2
CARD

October 2002
DIAGNOSTIC STATUS CODES
TRANSISTOR PUMP CONTROL Page 50

PUMP DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Voltage at capacitor (1C) is less than This status code will be displayed when the voltage at
-180 14 volts. P1 is less than 14 volts. This occurs typically in the run
mode of operation.
MEMORY RECALL
NO CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM FU3 KEY SWITCH
TO TRACTION
Pump control will not operate.
Circuits valid FU6 P10 - BDI

for POSSIBLE CAUSE PY7

P1 P2 P3 PY12
Pump (Line contactor controlled by traction P21 P19 P12 PY10
control).
Controller Line Contactor opened up during
PY11

SPEED LIMIT 2
SPEED LIMIT 3

SPEED LIMIT 1
run.
· Check connection from P17 to LINE FU1
Line coil (-) for loose connection.
· Check connection from battery (+)
to Line coil (+) for loose
connection.
· Check power connection from +

ARMATURE FIELD
battery (+) to contactor L. POS A1
· Check for blown fuse at pump - POWER
TO
CONNECTIONS
control. TRACTION
NEG A2
· Check for dirty contactor tips. CARD

PUMP DESCRIPTION OF CAUSE OF STATUS INDICATION

STATUS CODE STATUS
Battery voltage is less than 14 This status code will be displayed when the battery voltage
-181 volts. measured at P1 is less than 14 volts.
MEMORY RECALL
NO CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM FU3 KEY SWITCH
TO TRACTION
Circuits valid Pump control will not operate. FU6 P10 - BDI

for POSSIBLE CAUSE

PY7

Pump · Defective control fuse.

P1 P2 P3 PY12
P21 P19 P12 PY10
Controller Check control fuse for open PY11
SPEED LIMIT 2
SPEED LIMIT 3

SPEED LIMIT 1

circuit, replace fuse, if

necessary.
FU1
· Check connection from control LINE

fuse to pump P1 for loose

connections.

+
ARMATURE FIELD

POS A1
- POWER
CONNECTIONS TO
TRACTION
NEG A2
CARD

October 2002
INSTALLATION AND OPERATION MANUAL
SX TRANSISTOR CONTROL Page 51

Section 5. TRUCK MANAGEMENT MODULE (TMM) IMPORTANT NOTE: Status Codes 93, 94 and 95 are only
checked when a neutral signal is present (i.e., open start
Section 5.1 General Features switch or open F/R switch). The status code is displayed
and the speed limit enabled when the control is returned
The Truck Management Module is a multi-functional to the run mode. Do not use status code 93 speed limit for
accessory card (IC3645TMM7A), or an integral function of applications requiring immediate speed limit on switch
the SR Pump control when used with the SX Family of closure.
Traction controls. The Module provides the OEM with the
ability to initiate status codes or operator warning codes to Typical wiring diagrams and outline drawings for the
be displayed on the Dash Display whenever a normally TMM7A accessory card and SR family of Pump TMM
open switch or sensor wire provides a signal to the functions are shown in Sections 5.4 and 5.5.
Module.
Section 5.3 Installation
The TMM Module can be used to display a separate status
code indicating an over temperature of traction motors, WARNING: Before any adjustments, servicing or act
hydraulic motors, or any other device or system that can requiring physical contact with working components,
activate a switch that closes. jack drive wheels off the floor, disconnect the battery and
discharge the capacitors in the traction and pump
It can also be used as a Brush Wear Indicator (BWI). The controls, as explained in Section 4.4.
Brush Wear Indicator is designed to detect a “worn-out
brush” and display a fault code on the Dash Display to The TMM7A accessory card should be mounted to a flat
warn maintenance personnel that the motor brushes need surface (in any plane) in an area protected from water, oil
to be replaced before they wear to the point of causing and battery acid. Mounting dimensions are shown in
destructive damage to the motor commutator surface. The Section 5.5. Two (0.187 inch, 4.75mm) mounting holes are
BWI function is compatible with any sensor that short provided.
circuits to the motor armature to signal limits of brush
wear. Section 5.4 Connection Diagrams
Note: Motor armature must be in the positive side of the Section 5.4.1 TMM7A Card Connections
battery circuit.
Traction PL2
Section 5.2 Operation
4
9
1 20 19

The Module utilizes 9 OEM input points and 3 output points

that connect to the "Y" plug on the traction logic card. Due TMM7A CARD CONNECTIONS

to the low level signal value of this output, shielded wire 2 7 9 14

should always be used to insure proper operation. The 1 3 4 5 6 8 10 11 12 13 15

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
A1-1

A1-2

A2-1

A2-2

A3-1

A3-2

that point is closed to battery negative or positive, as 1 3 4

indicated. BATTERY
NEGATIVE
5 6 8 10 11 12

BATTERY
TMM7A Pump POSITIVE

Card Control Status

Terminal Terminal Code Connect To Section 5.4.2 Typical Brush Wear Sensor Connections
TB1 P16 90 * Neg
TB3 P11 91 Neg BRUSH WEAR SENSOR CONNECTIONS (TYPICAL)
TB4 P15 92 Neg
TB5 P3 93 * Pos 2 7 9 14

TB6 P4 93 * Pos
1 3 4 5 6 8 10 11 12 13 15
TB8 P5 94 Pos
TB10 P6 94 Pos
TB11 P8 95 Pos
TB12 P9 95 Pos ARM
1
ARM
2 ARM
1 2 1 2
* Status codes 90 and 93 can also be programmed with the 1 2 3

Handset to reduce the speed of the truck from 100 to 0

TRACTION PUMP PWR STEER

percent-on-time.
October 2002
INSTALLATION AND OPERATION MANUAL
SX TRANSISTOR CONTROL Page 52

Section 5.4.3 TMM Pump Control Connections

PUMP CONTROL CONNECTIONS

PL2 PL2 PL2 PL2 PL2 PL2 PL2 PL2 PL2 PL2 PL2
16 11 15 3 4 5 6 8 9 13 20

A1-1

A1-2

A2-1

A2-2

A3-1

A3-2
1 3 4
BATTERY 5 6 8 10 11 12
NEGATIVE
TRACTION
BATTERY PL2-14
POSITIVE

TRACTION
PL2-20

Section 5.5 TMM7A Outline Drawings

1 7
3 9
4
5
6
8 14
10
11
12
13
15

(85.3)
3.36

5.8
(147
.2
6.15 0) 1.60
(40.6)
156.
20

x .8
(20.3)

October 2002
 ADJUSTABLE FEATURES
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Section 6. SX FAMILY GE HANDSET START-UP DISPLAY SEQUENCE

INSTRUCTIONS

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 Verify Each LED Segment
and a keyboard for data entry. 8888
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
Display Code "-99"
personnel to perform the following functions of the SX For Four Seconds and
family of Controls: Activate Speed Limit
· Monitor existing system fault codes (if selected)
· Monitor intermittent random fault codes
· Monitor battery state of charge on systems with BDI
· Monitor hourmeter reading
· Monitor or adjust the following control functions: BDI Display or
Diagnostics Override
¨ Creep speed Blank Display
With Fault
¨ Armature Controlled Acceleration and 1A Time (no BDI used)
¨ Regenerative Braking Current Limit and Disable
¨ Armature and Field Current Limit
¨ Plugging Distance (Current)
¨ Pedal Position Plug Range or Disable Run Mode
¨ 1A Drop Out Current or Disable
¨ Speed Limit Points
¨ Truck Management Fault Speed Limit
¨ Internal Resistance Compensation for Battery BDI Display or
State of Charge Indication Diagnostics Override
Blank Display
¨ Battery Voltage ( 36/48 volts is auto ranging ) (no BDI used) With Fault
¨ Selection of Card Operation Type.
Key Switch
Warning: Before connecting or disconnecting the Handset Off
tool, turn off the key switch, unplug the battery and jack
up the drive wheels of the vehicle.
Display Traction Hourmeter
At the transistor control traction card, unplug the "Y plug" if For Four Seconds
the dash display is in use, and plug in the Handset to the
plug location "Y" on the control card. After installing the Display Pump Hourmeter
Handset tool, plug the battery in and turn the key switch on. For Four Seconds
The following is the start-up display sequence that will
occur:
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.
October 2002
ADJUSTABLE FEATURES
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Section 6.3 Set-up Function Procedures reading at the time the fault occurred. The first of the 16
status codes will be overwritten each time a new status
With the Handset connected, hold down the CONT key and code occurs. This stored status code register can be
turn on the key switch. This will place you in the set-up cleared from memory by using the Handset.
mode, ready to monitor or adjust control function settings.
ACCESSING STORED STATUS CODES
NOTE: The term “Push” means to depress key for
WITH GE HANDSET
approximately one second.

Section 6.3.1 Setup Mode Key Switch Off

SET-UP MODE Push ESC and CONT

At The Same Time

DISPLAY
ACTION SHOWS
REMARKS Release ESC and CONT
Key
Hold Down CONT Segment Check
And Turn On Key 8888 Displayed Hold Both the
Push ESC to ESC and CONT
Status Code Displayed Erase Stored Keys Down to
Selected Function No. Data Erase All 16
Push Function Number U005 Is Displayed Stored Codes

Push CONT Key

After One Second Stored Value For The
Time Delay 085 Function Is Displayed
Displays Battery Push ESC to
State-Of-Charge When Erase Stored
Display Value Fault Occurred Data
Push CONT 085 Will Blink

Push CONT Key

Change Value With Value Changes
Adjustment Knob 125 While Blinking
Push ESC to
Display Hourmeter Reading
Erase Stored
When Fault Occurred
New Value Stored And Data
Push STORE 125 Blinking Stops
Push CONT Key
Segment Check
Push ESC 8888 Displayed
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 “Y” Plug
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.

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

Handset Cable (Only) Part Number - 325B1002G1
The SX family of controllers furnishes a function register
that contains the last 16 “stored status codes” that shut Handset, Cable and Carrying Case Part Number –
down vehicle operation (a PMT type fault that is reset by IC3645LXHS1EC2
cycling the key switch) and the battery state of charge
February 2002
ADJUSTABLE FEATURES
SX TRANSISTOR CONTROLS Page 55

accelerator ohm input between 6K and 4.0K ohms is

LX g
HANDSET provided.
EVC
Range 2% to 15% on time
Set 0 to 255
Resolution 0.05% per set unit
Example: 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
CONT STORE
field personnel without the permission of the OEM.

FUNCTION 3 ARMATURE CONTROLLED

1 2 3 4 ACCELERATION
+ + (Push 3)

5 6 7 8 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. The 1A
9 10 11 12
contactor will automatically close 2.0 seconds after the
controlled acceleration stops and the accelerator input is
13 14 15 ESC less than 0.5 volts or less than 200 ohms.

Range 0.1 to 22.0 seconds

Set 0 to 255
Resolution 0.084 seconds per set unit
Section 6.4 Setup Functions for Traction Controller
Example: Setting of 20 = 1.8 seconds C/A
and 2.0 1A time
FUNCTION 1 MOTOR VOLTS TO ENABLE AUTO REGEN
(Push 1)
FUNCTION 4 ARMATURE CURRENT LIMIT
(Push 4)
This function allows for the adjustment of motor volts to
enable AutoRegen.
This function allows for the adjustment of the armature
current limit of the control. The rating of the control will
For a setting value of less than 25 (corresponding to a soft
determine the range of adjustment for this function. Please
release of auto regen and normal regen), the motor voltage
refer to the specification sheets and current limit curves for
to enable regen is calculated by multiplying the value of the
the control used in your vehicle.
setting by 0.375. For example, a setting of 16 will be
multiplied by 0.375 to enable regen at 6 motor volts.
Range See control C/L curves
Set 0 to 255
Vm = VAL(setting) X .375
Example: 0 = min. current, 255 = max.
current
For a setting value of greater than 25, the motor voltage to
enable auto regen is calculated by subtracting 25 from the
FUNCTION 5 REGEN RAMP RATE
setting value and multiplying that number by 0.375. For
(Push 5)
example, a setting of 33, the motor volts necessary to
enable auto regen is (33 - 25) x 0.375, or 3 volts.
This function allows for the adjustment of the rate that
regen braking is applied .
FUNCTION 2 CREEP SPEED
( Push 2 )
Armature current adjustment setting range: 0 to 126
Higher values of this setting correspond to a faster rate of
This function allows for the adjustment of the creep speed
change in armature current.
of the vehicle. Creep speed can be adjusted when an
accelerator input voltage between 3.9 and 3.3 volts or an
Field current adjustment setting range: 0 to 126
0 - 42 Fastest rate of change in field current
February 2002
ADJUSTABLE FEATURES
SX TRANSISTOR CONTROLS Page 56

43 - 84 Medium rate of change in field current

85 - 126 Slowest rate of change in field current Important Note: This function is used to optimize motor
and control performance, and this setting will be
FUNCTION 6 FW RATIO determined by GE and OEM engineers at the time of
(Push 6) vehicle development. This setting must not be changed by
field personnel without the permission of the OEM.
This function sets the ratio between armature and field
current when operating below the Field Weakening Start FUNCTION 9 REGEN BRAKING C/L
point. The setting represents the quantity of field current (Push 9)
changed for each 1 amp of armature current changed.
This function allows for the adjustment of the Regen
Max braking current limit. The higher the current, the shorter the
Volts Fld Ref stopping distance.
48 60
72/80 55 Resolution Example
Volts Min Max Set Per unit value If set at 20
The ratio value (VAL) is the set value divided by 10 and 48 183A 597A 0 to 255 1.625+183 215 amp
rounded to the lowest whole number. 72/80 26A 440A 0 to 255 1.625 58 amps

Example : Setting of 45 = 45/10 = 4.5 = 4 VAL. REGEN BRAKE IA = (VAL X 1.625) + 183 48 VOLTS

IFIELD = VAL ( IMOTOR X .024 ) FUNCTION 10 FIELD CURRENT FOR REGEN

( Push 10 )
FUNCTION 7 MIN FIELD CURRENT
( Push 7 ) This function allows for the adjustment of the field current
to be used during the regen braking mode.
This function allows the adjustment of the field weakening
level in order to set the top speed of the motor. Resolution Example
Volts Min Max Set Per unit value If set at 71
Resolution 48 0 60 51 to 255 .314 6.28A
Volts Min Max Set Per unit value 72/80 0 55 51 to 255 .269 amps 5.38A
48 0 60 51 to 255 .314
72/80 0 55 51 to 255 .269 Important Note: This function is used to optimize motor
and control performance and this setting will be
MIN IF = (VAL-51) X .314 (48 VOLT) determined by GE and OEM engineers at the time of
vehicle development. This setting must not be changed by
Important Note: This function is used to optimize motor field personnel without the permission of the OEM.
and control performance, and this setting will be
determined by GE and OEM engineers at the time of FUNCTION 12 MAX ARMATURE PERCENT ON
vehicle development. This setting must not be changed by ( Push 12 )
field personnel without the permission of the OEM.
This function allows for the adjustment of the motor speed
FUNCTION 8 MAX FIELD CURRENT limit (maximum battery volts to the motor). The dash
( Push 8 ) display mode selection enables the speed limit as well as
setting the level of speed limit.
This function allows for the adjustment of the maximum
field current in order to obtain the maximum torque of the FUNCTION 13 SPEED LIMIT 3
motor. ( Push 13 )

Resolution The SL3 set speed limit is activated by the Truck

Volts Min Max Set Per unit value Management Module 90,91 and also status code 99. See
48 0 60 51 to 255 .314 Section 5 for Truck Management Module details;
72/80 0 55 51 to 255 .269 Maintenance Speed Limit.

MAX IF = (VAL-51) X .314 (48 VOLT)

February 2002
ADJUSTABLE FEATURES
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48 volts Between 45 and 69

72 volts Between 70 and 80
FUNCTION 14 INTERNAL RESISTANCE 80 volts Between 81 and 183
COMPENSATION 36/48 volts Between 184 and 250
( Push 14 ) No BDI Between 251 and 255

This function is used when the Battery Discharge Indicator

is present. Adjustment of this function will improve the The following functions have function numbers larger
accuracy of the BDI. In order to determine this setting the than the numbers on the Handset keyboard. To access
voltage drop of the battery under load must first be these functions. Push the CONT key and the number
calculated by the following method. This function can be shown in the following instructions at the same time.
changed by the dash display mode selection button. THE SEAT SWITCH MUST BE OPEN.

1. On a fully charged battery, record the open circuit

voltage (Vo) by measuring the voltage at the control
positive and negative power terminals.
2. Load the traction motor to 100 amps in 1A and record the .FUNCTION 16 STALL TRIP POINT WITH % ON-TIME
voltage (VL) at the control positive and negative power
terminal. This function allows for the adjustment of control percent
3. Calculate voltage drop (VDrop) as follows: on time for the stall motor trip point
VDrop = VO - VL
4. Use the table below to determine the appropriate setting Control % On time = 163 -(Set Point Val)*.892
using the calculated VDrop as a reference.
If 163 or greater, then “0.0” % on time
INTERNAL RESISTANCE COMPENSATION If 51 or less, then “100.”% on time
TABLE
FUNCTION 17 CARD TYPE SELECTION
Setting VDrop Setting VDrop ( Push CONT 2 )
2 11.44 17 01.34
This function allows for the selection of the card type used
3 07.60 18 01.27
for your vehicle's application. The table below shows the
4 05.72 19 01.20
setting to select card application type, depending on which
5 04.57 20 01.14 control card is used.
6 03.81 21 01.09
7 03.27 22 01.04 FUNCTIONS REGEN
8 02.86 23 00.99 BDI Lockout Disable Auto Regen 50 to 54
9 02.54 24 00.95 BDI Lockout Enable AutoRegen 55 to 59
10 02.28 25 00.91 Settings for these functions should be made within the
11 02.08 26 00.88 ranges indicated above.
12 01.90 27 00.85
13 01.76 28 00.82 Warning: These settings must be changed by authorized
14 01.63 29 00.79 personnel only, following instructions supplied by the
15 01.52 30 00.76 vehicle manufacturer. Card type selection must be made
16 01.43 31 00.74 within the capabilities of the control panel used and the
supporting electro mechanical devices. Failure to comply
FUNCTION 15 BATTERY VOLTS with proper application standards could result in mis-
(Push l5) operation or damage to the control and/or motors.

This function allows for the adjustment of voltage range for FUNCTION 18 LINE CONTACTOR TIME DELAY
controls equipped with the Battery Discharge Indication ( Push CONT 3 )
function. In order for the BDI to operate properly, the
setting as shown in the table must be entered: This function allows for the adjustment of the run mode
after the seat switch opens.
Battery volts Set units
24 volts Between 0 and 31 Range 1.5 to 65 seconds
36 volts Between 32 and 44 Setting Between 0 and 128
February 2002
ADJUSTABLE FEATURES
SX TRANSISTOR CONTROLS Page 58

Resolution 0.5 seconds per set unit

Range 0 to 414 Amps
Example: Setting of 20 = (20 x 0.5) + 1.5 = 11.5 seconds Setting 0 to 255
Resolution 1.625 per set unit
Or: I MOTOR FWS = VAL. x 1.625

Range 0.5 to 63 seconds Example: Setting of 20 = 32.5 amps

Setting Between 129 and 255
Resolution 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
Note: Line contactor drop out will be 1.5 seconds after the microprocessor. Because absolute memory locations need
seat switch opens. to be known, this function should not be used without
detailed instructions from the GE application engineer.
FUNCTION 19 MAINTENANCE CODE TENS AND UNITS
HOURS SET This function should only be adjusted by the vehicle OEM.
( Push CONT 4 ) 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 0 to 99
Set 0 to 99 This function sets the ratio between armature and field
Example 9999 Hours current when operating below the maximum field current
and above the Field Weakening Start point. The setting
FUNCTION 20 MAINTENANCE CODE THOUSANDS represents the quantity of field current changed for each 1
AND HUNDREDS HOURS SET amp of armature current changed.
( Push CONT 5 )
Volts Max Field Ref
This function allows for the adjustment of the thousands 48 60
and hundreds hours of the maintenance code activation 72/80 55
time.
The ratio value (VAL) is the set value divided by 10 and
Range 0 to 240 rounded to the lowest whole number.
Set 0 to 240
Example 9999 Hours Example : Setting of 45 = 45/10 = 4.5 = 4 VAL.
FUNCTION 21 AUTO REGEN BRAKING C/L IFIELD = VAL ( IMOTOR X .0240 )
(Push CONT 6)
FUNCTION 28 STORED STATUS CODE COUNT POINTER
This function allows for the adjustment of the Regen ( Push CONT 13)
braking current limit. The higher the current the shorter the
stopping distance. This register contains the location of the last stored status
code recorded of the 16 stored status codes. These stored
Setting greater than 143 disables this function.
status codes have caused a PMT controller shutdown
and/or disruption of normal vehicle operation.
[(
AUTO REGEN = REGEN C/L - FNT 21-51
-
[ (6.50
C/L AMPS VAL VAL
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
FUNCTION 24 FIELD WEAKENING START
code pointer number" [the number shown in (bold italics)
( Push CONT 9)
in the HS (Handset) number column] on the memory map,
with the number obtained from Function 28. This will be the
This function allows for setting the armature current at
last stored status code recorded.
which minimum field current will be achieved .
February 2002
ADJUSTABLE FEATURES
SX TRANSISTOR CONTROLS Page 59

This FIELD WEAKENING START takes effect when the

Note: When scrolling through the stored status code Mode 1 settings are called for by the interactive Dash
register, the register always starts at status code 1 and Display.
scrolls to status code 16. Instructions for scrolling the
register are in section 6.3.2 of this instruction booklet. FUNCTION 50 MODE 1 FW RATIO
( Push CONT 3 )

DASH DISPLAY INTERACTIVE MODES This function sets the ratio between armature and field
current when transitioning from minimum field to maximum
The following functions (functions 48 through 62) are field current. The setting represents the quantity of field
mode settings that are activated from the Interactive Dash current changed for each 1 amp of armature current
Display. Each function must be set using the logic table changed.
shown below. If you try to set this function outside these
guidelines, an error code will be displayed to prompt you Max
to enter the correct setting: Volts Fld Ref
If “80” is displayed, the setting is too low. 48 60
If “81” is displayed, the setting is too high. 72/80 55

The ratio value (VAL) is the set value divided by 10 and

The following functions have function numbers larger rounded to the lowest whole number.
than the numbers on the Handset keyboard. To access
these functions. Push the CONT key and the number Example : Setting of 45 = 45/10 = 4.5 = 4 VAL.
shown in the following instructions at the same time.
THE SEAT SWITCH MUST BE CLOSED. IFIELD = VAL ( IMOTOR X .024 )

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
FUNCTION 51 MODE 1 MAX ARMATURE % ON
( Push CONT 1)
( Push CONT 4)
This function allows for the adjustment of the rate of time it
This function allows for the adjustment of the speed limit
takes for the control to accelerate to 100% applied battery
(maximum battery volts to the motor) when the SL1 limit
voltage to the motor on hard acceleration.
switch input signal is received by the control card. The SL1
limit switch is a normally closed switch connected to
Range 0.025 to 6.3 seconds
battery negative; the switch opening enables speed limit.
Set 0 to 255
Resolution 0.025 seconds per set unit
Range 100% to 0% battery volts
Example: Setting of 20 = 0.5 seconds
Set 51 to 180
Resolution 0.78 % per set unit
This C/A takes effect when the Mode 1 settings are called
Example Setting of 71 = 84.4 % battery
for by the interactive Dash Display.
volts
This MAX ARMATURE % ON takes effect when the Mode 1
FUNCTION 49 MODE 1 FIELD WEAKENING START
settings are called for by the interactive Dash Display.
( Push CONT 2)
FUNCTION 52 MODE 2 ARMATURE CONTROLLED
This function allows for setting the armature current at
ACCELERATION
which minimum field current will achieved .
( Push CONT 5)
Range 0 to 414 Amps
Same as Function 48.
Setting 0 to 255
Resolution 1.625 per set unit
This C/A takes effect when the Mode 2 settings are called
for by the interactive Dash Display.
Example: Setting of 20 = 32.5 amps
FUNCTION 53 MODE 2 FIELD WEAKENING START
I M FWS = VAL x 1.625
( Push CONT 6)
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FUNCTION 60 MODE 4 ARMATURE

Same as Function 49. CONTROLLED ACCELERATION
( Push CONT 13)
This FIELD WEAKENING START takes effect when the
Mode 2 settings are called for by the interactive Dash Same as Function 48.
Display.
This C/A takes effect when the Mode 4 settings are called
FUNCTION 54 MODE 2 FW RATIO for by the interactive Dash Display.
( Push CONT 7 )
FUNCTION 61 MODE 4 FIELD WEAKENING START
Same as Function 50. ( Push CONT 14)

This FW RATIO takes effect when the Mode 2 settings are Same as Function 49.
called for by the interactive Dash Display.
This FIELD WEAKENING START takes effect when the
FUNCTION 55 MODE 2 MAX ARMATURE % ON Mode 4 settings are called for by the interactive Dash
( Push CONT 8 ) Display.

Same as Function 51. FUNCTION 62 MODE 4 FW RATIO

( Push CONT 15 )
This MAX ARMATURE % ON takes effect when the Mode 2
settings are called for by the interactive Dash Display. Same as Function 50.

This FW RATIO takes effect when the Mode 4 settings are

FUNCTION 56 MODE 3 ARMATURE called for by the interactive Dash Display.
CONTROLLED ACCELERATION
( Push CONT 9) FUNCTION 63 MODE 4 MAX ARMATURE % ON
( Push CONT ESC )
Same as Function 48.
Same as Function 51.
This C/A takes effect when the Mode 3 settings are called
for by the interactive Dash Display. This MAX ARMATURE % ON takes effect when the Mode 4
settings are called for by the interactive Dash Display.
FUNCTION 57 MODE 3 FIELD WEAKENING START
( Push CONT 10)

Same as Function 49.

This FIELD WEAKENING START takes effect when the

Mode 3 settings are called for by the interactive Dash
Display.

FUNCTION 58 MODE 3 FW RATIO

( Push CONT 11 )

Same as Function 50.

This FW RATIO takes effect when the Mode 3 settings are

called for by the interactive Dash Display.

FUNCTION 59 MODE 3 MAX ARMATURE % ON

( Push CONT 12 )

Same as Function 51.

This MAX ARMATURE % ON takes effect when the Mode 3
settings are called for by the interactive Dash Display.

February 2002
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Section 6.5 Summary of Current Limit Adjustments

Maximum field
The " maximum field current" setting current is fixed at
is adjusted by Function 8. This 60.0 amps
function, along with the"armature
current limit", Function 4, sets the
maximum torque of the motor.

MAXIMUM

The " ratio" setting is adjusted by Function 26.

This function sets the ratio between armature
and field current when operating,MOTOR
I 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 is adjusted by

FIELD CURRENT

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 is adjusted
by Function 7. The function
sets the top speed of the
motor. If used.

The " field weakening start"

setting is adjusted by Function
24. This function sets the
armature current at which
minimum field current will be
achieved .

ZERO
ARMATURE CURRENT
MAXIMUM
ZERO

The "full load transition point"

is calculated by the control.This
function sets the maximum field
current transition point at
approximately 500A armature
current.
The " ratio-2 " setting is adjusted by Function 6.
The "armature current limit"
This function sets the ratio between armature
setting is adjusted by Function 4.
and field current when operating,MOTOR
I is
The function along with the
below FWS. Setting is the value of field current
"maximum field current",
changed for each 100 amps of armature current
Function 8, sets the maximum
changed.
torque of the motor.

October 2002
ADJUSTABLE FEATURES
TRANSISTOR PUMP CONTROLS Page 62

Section 6.6 Setup Functions for Hydraulic Pump Control This function allows for the adjustment of the rate of time it
takes for the control to add the internal resistance
FUNCTION 1: NOT APPLICABLE compensation voltage that is applied to the motor. This
function will add 0.375 volts to the motor at the rate of time
This function is not applicable to this type of control and adjusted until the total IR compensation voltage has been
should not be adjusted. added.

FUNCTION 2: INTERNAL RESISTANCE Range 0.0015 to 0.383 seconds

COMPENSATION START Setting 0 to 255
(Push 2) Resolution 0.0015 seconds per set unit

This function allows for the adjustment of the current level Example: Setting of 20 = 0.032 seconds
at which the internal resistance compensation feature For example, if you had selected 2.08 volts from Function 16
(Function 16) will take effect. 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
Range 0 to 1325 amps
Setting 52 to 255 FUNCTION 11: SPEED LIMIT 1 (SL1)
Resolution 6.5 amps per set unit (Push 11)

Example: Setting of 72 = (72-52) x 6.5 = 130 amps This function allows for the adjustment of the speed limit
(maximum battery volts to the motor) when the SL1 limit
FUNCTION 3: CONTROLLED ACCELERATION switch input signal is received by the control card. SL1
(Push 3) limit switch is a normally open switch connected to battery
negative, the switch closing enables speed limit.
This function allows for the adjustment of the rate of time it
takes for the control to accelerate to 100% applied battery Range 0% to 100% battery volts
voltage to the motor on hard acceleration. The P1A Setting 0 to 255
contactor will automatically close 0.2 seconds after the Resolution 0.375 volts per set unit
controlled acceleration stops and the accelerator input is
less than 0.5 volts, or less than 200 ohms. Example: Setting of 50=18.75 volts

Range 0.1 to 5.5 seconds FUNCTION 12: SPEED LIMIT 2 (SL2)

Setting 0 to 255 (Push 12)
Resolution 0.021 seconds per set unit
Same as Function 11 except using SL2 limit switch for input.
Example: Setting of 20 = 0.52 seconds C/A and 0.72 seconds
1A time FUNCTION 13: SPEED LIMIT 3 (SL3)
(Push 13)
FUNCTION 4: CURRENT LIMIT
(Push 4) Same as Function 11 except using SL3 limit switch for input.

This function allows for the adjustment of the current limit FUNCTION 14: NOT APPLICABLE
of the control. The rating of the control will determine the
range of adjustment for this function. Please refer to the This function is not applicable to this type of control and
OEM operating instructions for the control used in your should not be adjusted.
vehicle.
Note: The following functions have function numbers
Range See OEM control C/L curves larger than the numbers on the Handset keyboard. To
Setting 0 to 255 access these functions, push the CONT key and the
number shown in the following instructions at the same
Example: 0 = min. current, 255 = max. current time. THE KEY SWITCH MUST BE CLOSED.

FUNCTION 7: INTERNAL RESISTANCE

COMPENSATION RATE
(Push 7)

October 2002
ADJUSTABLE FEATURES
TRANSISTOR PUMP CONTROLS Page 63

FUNCTION 16: SPEED / TORQUE COMPENSATION and the supporting electro-mechanical devices. Failure to
(Push CONT 1) comply with proper application standards could result in
mis-operation or damage to the control and/or motors.
This function is used to stabilize pump speed at heavy
loads. The voltage selected will be added to the motor at FUNCTION 28: FAULT COUNT POINTER
each 100 amp increment starting at the value set in (Push CONT 13)
Function 2. The voltage compensation selected will be
added in increments of 0.375 volts until the entire voltage is This register contains the location of the last stored status
added. For example, a setting of 2 will be added in 30 steps code recorded of the 16 stored status codes. These stored
of 0.375 volts each whereas, a setting of 4 will be added in status codes have caused a PMT controller shutdown
15 steps of 0.375 volts each. and/or disruption of normal vehicle operation.

SPEED / TORQUE To determine which stored status code was the last one
COMPENSATION TABLE recorded, read the number stored in Function 28. Using the
VOLTAGE VOLTAGE Memory Map (See Section 8.1) for your logic card, match
SETTING DROP SETTING DROP the “stored status code pointer number” (the number
2 11.44 17 1.34 shown in (bold italics) in the HS (Handset) number column)
3 7.60 18 1.27 on the memory map, with the number obtained from
4 5.72 19 1.20 Function 28. This will be the last stored status code
5 4.57 20 1.14 recorded.
6 3.81 21 1.09
7 3.27 22 1.04 Note: When scrolling the stored status code register, the
register always starts at status code 1 and scrolls to
8 2.86 23 0.99
status code 16. Instructions for scrolling the register are
9 2.54 24 0.95
in Section 6.3.2 of this instruction booklet.
10 2.28 25 0.91
11 2.08 26 0.88
12 1.90 27 0.85 Note: The following functions have function numbers
13 1.76 28 0.82 larger than the numbers on the Handset keyboard. To
14 1.63 29 0.79 access these functions, push the CONT key and the
15 1.52 30 0.76 number shown in the following instructions at the same
16 1.43 31 0.74 time. THE KEY SWITCH MUST BE OPEN.

FUNCTION 17: CARD TYPE SELECTION FUNCTION 48: MODE 1 - CONTROLLED ACCELERATION
(Push CONT 2) (Push CONT 1)
This function allows for the adjustment of the rate of time it
This function should be set in accordance with the control takes for the control to accelerate to 96% applied battery
type in use in the vehicle: voltage to the motor on hard acceleration.

Without Pump Range 0.1 to 22.0 seconds

Function Ctr/PMT Setting 0 to 255
High C/L Resolution 0.084 seconds per set unit
BDI Lockout 27 to 35
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 FUNCTION 49: MODE 1 - SPEED LIMIT 2 (SL2)
operate. This control will stop operation when the battery (Push CONT 2)
state of charge reaches 10%.
This function allows for the adjustment of the speed limit
Settings for these functions should be made in between the (maximum battery volts to the motor) when the SL2 limit
values shown. switch input signal is received by the control card. SL2
limit switch is a normally open switch connected to battery
Warning: These setting must be changed by authorized negative, the switch closing enables speed limit.
personnel only, following instructions supplied by the
manufacturer. Card type selection must be made within Range 0% to 100% battery volts
the capabilities of the TRANSISTOR control panel used Setting 0 to 255
February 2002
ADJUSTABLE FEATURES
TRANSISTOR PUMP CONTROLS Page 64

Resolution 0.375 volts per set unit FUNCTION 59: NOT APPLICABLE

Example: Setting of 50=18.75 volts This function is not applicable to this type of control and
should not be adjusted.
FUNCTION 50: MODE 1 - SPEED LIMIT 3 (SL3)
(Push CONT 3) FUNCTION 60: MODE 4 - CONTROLLED ACCELERATION
(Push CONT 13)
This function allows for the adjustment of the speed limit
(maximum battery volts to the motor) when the SL3 limit Same as function 48.
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)
Range 0% to 100% battery volts
Setting 0 to 255 Same as Function 49.
Resolution 0.375 volts per set unit
FUNCTION 62: MODE 4 - SPEED LIMIT 3 (SL3)
Example: Setting of 50=18.75 volts (Push CONT 15)

FUNCTION 52: MODE 2 - CONTROLLED ACCELERATION Same as Function 50.

(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.

February 2002
INSTALLATION AND OPERATION MANUAL
SX TRANSISTOR CONTROL Page 65

Section 7. DASH DISPLAYS From the Dash Display, the operator may select any of four
pre-set interactive modes consisting of (4) Controlled
Section 7.1 Application Acceleration levels, (4) Field Weakening Pick Up levels and
(4) Speed Limit levels.
The SX family Standard and Interactive Dash Displays
allow the operator and maintenance personnel easy These interactive modes are “pre-set” using the Handset
access to truck operation information and real-time system (Functions 48 - 63) or a personal computer (Functions 97 -
diagnostics of the controller, motor and various 112). This feature allows the operator to select the best
accessories. Hourmeter readings, battery discharge vehicle performance for changing factory (task) conditions.
information, maintenance information and system status
codes are clearly displayed during startup and running The Custom Dash Display incorporates all the features and
modes. Shielded cable connections are made to the Dash functions of the Standard Dash Display, in addition to the
Display by means of five (5) 22-gage wires to the “Y” Plug following customer options:
of the traction and hydraulic pump controls.
· LED graphics to display Battery Discharge Indication
Section 7.2 Standard Dash Displays status.
· 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
g GE Electric Vehicle
Motors & Controls displays Status Codes can be used to scroll the last 16
“Stored Status Codes” that shut down vehicle operation
with a PMT fault.

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 T=Traction Only

Emitting Diode (LED) instrument that displays the GE LX, ZX, P=Traction & Pump
and SX Status Codes, Hourmeter Readings, Battery
Discharge Indication, and Maintenance Required Code. 3=Round Face with four
The four LED's above the symbols indicate the active display symbols
readout mode.
For Custom Dash Displays,
Section 7.3 Interactive Custom Dash Displays contact your vehicleOEM.

+ Reference
AMP#102241-3 Dash Display mating plug
BATTERY

EVT100ZX PUSH AMP#1-87195-8 Dash Display mating pin

44A723596-G09 Dash Display plug kit
- PUSH
AMP#175965-2 "Y" Plug
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.

October 2002
INSTALLATION AND OPERATION MANUAL
SX TRANSISTOR CONTROL Page 66

Section 7.4 Start-Up Display Sequence

Section 7.5 Outline Drawings

START-UP DISPLAY SEQUENCE

Key Switch On
g GE Electric Vehicle
Motors & Controls

Verify Each LED Segment

+ -
8888
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 CONNECTOR OMITTED
Activate Speed Limit IF NOT REQUIRED
PUMP

2.45 (62.2)

2.00 (50.8)
(if selected)

0.19 TRACTION
BDI Display or (4.8)
Diagnostics Override
Blank Display
(no BDI used) With Fault

PY3
PY4
Run Mode PY2
PY1
PUMP
1 2 3 4 5
BDI Display or Wiring connections to "Y"
Diagnostics Override
Blank Display
(no BDI used) With Fault BACK VIEW OF DISPLAY plugs of Traction & Pump
controls.
Key Switch 5 4 3 2 1
TRACTION
Off
PY3
PY4
Display Traction Hourmeter PY2
For Four Seconds PY1
PY5
Display Pump Hourmeter
For Four Seconds

October 2002
RS-232 MEMORY MAP TABLES
SX TRANSISTOR CONTROL Page 67

Section 8.0 MEMORY MAPS

Section 8.1 Traction Control

E2 Func No. HS Traction Control Access By Restrictions

No. Function
0 1 1 NOT USED HS or PC None
1 2 2 Creep HS or PC None
2 3 3 Controlled Acceleration HS or PC None
3 4 4 Armature Current Limit HS or PC None
4 5 5 Plug Current Limit HS or PC None
5 6 6 Ratio 2 HS or PC None
6 7 7 Minimum Field Current HS or PC None
7 8 8 Maximum Field Current HS or PC None
8 9 9 Regen Current Limit HS or PC None
9 10 10 Field Current for Regen HS or PC None
10 11 11 Speed Limit 1 HS or PC None
11 12 12 Speed Limit 2 HS or PC None
12 13 13 Speed Limit 3 and VMM HS or PC None
13 14 14 IR Compensation HS or PC None
14 15 15 Battery Volts Select HS or PC None
15 16 16 Pedal Position Plug HS or PC None
16 17 17 Card Type Select HS or PC None
17 18 18 Line Contactor Time Delay HS or PC None
18 19 19 Maintenance Code HM (Tens/Units) HS or PC None
19 20 20 Maintenance Code HM (Thou/Hun) HS or PC None
20 21 21 Auto Regen HS or PC None
21 22 22 Mode Reference HS or PC For DD on power up
22 23 23 Field PWM Gain HS or PC None
23 24 24 FW Start HS or PC None
24 25 25 Monitor HS or PC GE Temporary Storage
25 26 26 Ratio HS or PC GE Temporary Storage
26 27 27 HM Minutes HS or PC GE Temporary Storage
27 28 28 Fault Count Pointer HS or PC None
28 29 29 Aux HM (Tens/Ones) Adj HS or PC None
29 30 30 Aux HM (Thou/Hun) Adj HS or PC None
30 31 Aux HM (Tens/Ones) PC Only None
31 32 Aux HM (Thou/Hun) PC Only None
32 33 (18) Stored Status Code #1 PC Only Reset to Zero Only
33 34 BDI 1 PC Only Reset to Zero Only
34 35 Hours (Tens/Ones) 1 PC Only Reset to Zero Only
35 36 Hours (Thou/Hun) 1 PC Only Reset to Zero Only
36 37 (20) Stored Status Code #2 PC Only Reset to Zero Only
37 38 BDI 2 PC Only Reset to Zero Only
38 39 Hours (Tens/Ones) 2 PC Only Reset to Zero Only
39 40 Hours (Thou/Hun) 2 PC Only Reset to Zero Only
40 41 (22) Stored Status Code #3 PC Only Reset to Zero Only
41 42 BDI 3 PC Only Reset to Zero Only
42 43 Hours (Tens/Ones) 3 PC Only Reset to Zero Only
October 2002
RS-232 MEMORY MAP TABLES
SX TRANSISTOR CONTROL Page 68

E2 Func No. HS Traction Control Access By Restrictions

No. Function
43 44 Hours (Thou/Hun) 3 PC Only Reset to Zero Only
45 46 BDI 4 PC Only Reset to Zero Only
46 47 Hours (Tens/Ones) 4 PC Only Reset to Zero Only
47 48 Hours (Thou/Hun) 4 PC Only Reset to Zero Only
48 49 (26) Stored Status Code #5 PC Only Reset to Zero Only
49 50 BDI 5 PC Only Reset to Zero Only
50 51 Hours (Tens/Ones) 5 PC Only Reset to Zero Only
51 52 Hours (Thou/Hun) 5 PC Only Reset to Zero Only
52 53 (28) Stored Status Code #6 PC Only Reset to Zero Only
53 54 BDI 6 PC Only Reset to Zero Only
54 55 Hours(Tens/Ones) 6 PC Only Reset to Zero Only
55 56 Hours(Thou/Hun) 6 PC Only Reset to Zero Only
56 57 (30) Stored Status Code #7 PC Only Reset to Zero Only
57 58 BDI 7 PC Only Reset to Zero Only
58 59 Hours(Tens/Ones) 7 PC Only Reset to Zero Only
59 60 Hours(Thou/Hun) 7 PC Only Reset to Zero Only
60 61 (32) Stored Status Code #8 PC Only Reset to Zero Only
61 62 BDI 8 PC Only Reset to Zero Only
62 63 Hours;(Tens/Ones) 8 PC Only Reset to Zero Only
63 64 Hours(Thou/Hun) 8 PC Only Reset to Zero Only
64 65 (34) Stored Status Code #9 PC Only Reset to Zero Only
65 66 BDI 9 PC Only Reset to Zero Only
66 67 Hours(Tens/Ones) 9 PC Only Reset to Zero Only
67 68 Hours(Thou/Hun) 9 PC Only Reset to Zero Only
68 69 (36) Stored Status Code #10 PC Only Reset to Zero Only
69 70 BDI 10 PC Only Reset to Zero Only
70 71 Hours(Tens/Ones) 10 PC Only Reset to Zero Only
71 72 Hours(Thou/Hun) 10 PC Only Reset to Zero Only
72 73 (38) Stored Status Code #11 PC Only Reset to Zero Only
73 ; 74 BDI 11 PC Only Reset to Zero Only
74 75 Hours(Tens/Ones) 11 PC Only Reset to Zero Only
75 76 Hours(Thou/Hun) 11 PC Only Reset to Zero Only
76 77 (40) Stored Status Code #12 PC Only Reset to Zero Only
77 78 BDI 12 PC Only Reset to Zero Only
78 79 Hours(Tens/Ones) 12 PC Only Reset to Zero Only
79 80 . Hours(Thou/Hun) 12 PC Only Reset to Zero Only
80 81 (42) Stored Status Code #13 PC Only Reset to Zero Only
81 82 BDI 13 PC Only Reset to Zero Only
82 83 Hours(Tens/Ones) 13 PC Only Reset to Zero Only
83 84 Hours(Thou/Hun) 13 PC Only Reset to Zero Only
84 85 (44) Stored Status Code # 14 PC Only Reset to Zero Only
85 86 BDI 14 PC Only Reset to Zero Only
86 87 Hours(Tens/Ones) 14 PC Only Reset to Zero Only
87 88 Hours(Thou/Hun) 14 PC Only Reset to Zero Only
88 89 (46) Stored Status Code # 15 PC Only Reset to Zero Only
89 90 BDI 15 PC Only Reset to Zero Only
90 91 Hours (Tens/Ones) 15 PC Only Reset to Zero Only
October 2002
RS-232 MEMORY MAP TABLES
SX TRANSISTOR CONTROL Page 69

E2 Func No. HS Traction Control Access By Restrictions

No. Function
90 91 Hours (Tens/Ones) 15 PC Only Reset to Zero Only
91 92 Hours (Thou/Hun) 15 PC Only Reset to Zero Only
92 93 (48) Stored Status Code #16 PC Only Reset to Zero Only
94 95 Hours (Tens/Ones) 16 PC Only Reset to Zero Only
95 96 Hours (Thou/Hun) 16 PC Only Reset to Zero Only
96 67 48 Dash Display CA-1
97 98 49 Dash Display FWS-1 HS or PC None
98 99 50 Dash Display Ratio2-1 HS or PC None
99 100 51 Dash Display Speed Limit 2 - 1 HS or PC None
100 101 52 Dash Display CA-2 HS or PC None
101 102 53 Dash Display FWS-2 HS or PC None
102 103 54 Dash Display Ratio2-2 HS or PC None
103 104 55 Dash Display Speed Limit 2 - 2 HS or PC None
104 105 56 Dash Display CA-3 HS or PC None
105 106 57 Dash Display FWS-3 HS or PC None
106 107 58 Dash Display Ratio2-3 HS or PC None
107 108 59 Dash Display Speed Limit 2 - 3 HS or PC None
108 109 60 Dash Display CA-4 HS or PC None
109 110 61 Dash Display FWS-4 HS or PC None
110 111 62 Dash Display Ratio2-4 HS or PC None
111 112 63 Dash Display Speed Limit 2 - 4 HS or PC None
112 113 Secure HM (Tens/Ones) PC Only OEM Read Only
113 114 Secure HM (Thou/Hun) PC Only OEM Read Only
114 115 Secure Aux HM (Tens/Ones) PC Only OEM Read Only
115 116 Secure Aux HM (Thou/Hun) PC Only OEM Read Only
116 117 Reserved PC Only GE Future Use
117 118 Reserved PC Only GE Future Use
118 119 Reserved PC Only GE Future Use
119 120 Reserved PC Only GE Future Use
120 121 OEM Use PC Only None
121 122 OEM Use PC Only None
122 123 OEM Use PC Only None
123 124 OEM Use PC Only None
124 125 OEM Use PC Only None
125 126 OEM Use PC Only None
126 127 OEM Use PC Only None
127 128 OEM Use PC Only None
Numbers in (bold italics) are Stored Status Code pointers.

October 2002