Terex 150 Ton ACOHV Propulsion Systems Fault Codes DTC

GET–6869
PTU
VEHICLE TEST, DIAGNOSTIC, AND w PTU
INSTRUCTIONS FOR
150 TON AC OHV PROPULSION SYSTEMS
Copyright 2003 General Electric Company.

Company. All rights reserved. This copyrighted document may be reproduced free of charge by General
Electric Company customers (OEM’s) and their customers, if such reproduction is used exclusively in connection with equipment used in those
customers’ internal operations.
These instructions do not purport to cover all details or variations in equipment

equipment nor to provide for every possible contingency to be met in connection with installation, operation,
operation, or mainte-
nance. Should further information be desired or should particular problems arise which are not covered sufficiently for the user’s purposes, the matter should be referred to the General
Electric Company. Any applicable Federal, State or local regulations or company safety or operating rules must take precedence over any instructions given in this material. GE has no
obligation to keep the material up to date after the original publication.
THERE ARE NO WARRANTIES OF ACCURACY, MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE.
Verify numbers for parts, tools, or material by using the Renewal Parts or Tool Catalogs, or
contact your General Electric representative for assistance.
Do not order from this publication.
https://www.besttruckmanuals.com/

VTI For 150 Ton AC OHV Propulsion Systems, GET–6869
CONTENTS
Page
1. OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1. TO
T OOLS AND TEST EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2. HANDLING ELECTRONIC PANEL PRINTED CIRCUIT CARDS . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. PORTABLE TEST UNIT (PTU) DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1. w PTU
PTU AB
A BBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2. OHV w PTU
PTU TO TOOLBOX OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.1 .Real–Time Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.2. Stored Event Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.3 .Statistical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.4. Setting Propulsion System Configuration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2.5. Software Downloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2.6. Data Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2.7. System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2.8. Self–Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2.9. Integrated Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2.10. One–Step Downloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3. w PTU
PTU S SC
CREEN SELECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4. w PTU
PTU ST
STARTUP SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5. View Datalogger and Data Graph Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.6. SASAVING SCREEN DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7. PASSWORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3. SELECTED SCREEN DESCRIPTIONS AND FUNCTIONS . . . . . . . . . . . . . . . . . . . . . 11

3.1. Product Service Data Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2. Truck Specific Data Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3. Vi
View Overspeeds Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.4. Set Wheel Motor Types Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.5. MO
MONITOR REAL TIME DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.5.1. PSC – Real Time Data Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.5.2. PSC – Serial Link Data Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.5.3. PSC – Analog Inputs Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.5.4. PSC – Temperatures Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.6. CHECK PSC MODE LOGIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.6.1. Accessing PSC Logic Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.7. CHECK TCI ACCEL INHIBIT LOGIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.7.1. Accessing TCI Accel Inhibit Logic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.8. CONSOLIDATED TRUCK DATA SAVE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4. CONFIGURATION FILES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1. GE Configuration File Name Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2. View Truck Configuration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3. GE/OEM Default Configuration Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.4. GE/OEM Configuration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.5. Saving New Configuration Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
i

GET–6869, VTI For 150 Ton AC OHV Propulsion Systems
CONTENTS (Cont’d)
Page
4.6. Configuration File Destination Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.7. Configuration File Source Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5. INSTALLING AC PROPULSION SYSTEM SOFTWARE ON TRUCK . . . . . . . . . . . 33

5.1. Selecting The GE Configuration File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.2. Create The Truck/Mine Configuration File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3. SAVE EXISTING TRUCK DATA ((N Not Applicable to New Trucks) . . . . . . . . . . . . . . . . . . . . . . . . 39
5.4. PROGRAM TCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.5. PROGRAM PSC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.6. Program Inverters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.7. CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6. TRUCK START–UP PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

6.1..
6.1 CIRCUI
CIRCUIT
T CONTI
CONTINUI
NUITY
TY AND
AND R RESI
ESIST STANCE
ANCE CHECKS CHECKS
AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.1.1. VOM Circuit and Component Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.2. MEGGER TEST FOR GROUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.2.1. Preparation For Megger Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.2.2. MMeegger Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.2.3. Restore Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.3. TROUBLESHOOTING FOR GROUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.4. LOW VOLTAGE POWER SUPPLY CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.4.1. Preparation for Power Supply Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.4.2. Power Supply Voltage Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.5. PS
PSC AND TCI CARD CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.6. LOAD AC OHV PROPULSION SYSTEM SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.7. REST MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.8. PSC MANUAL DIGITAL INPUT/OUTPUT TEST PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . 52
6.9. PEDAL, POT, AND LEVER ADJUSTMENT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.10. GAUGE CALIBRATION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.11. CONFIGURATION CHANGES DUE TO CALIBRATION CHECKS . . . . . . . . . . . . . . . . . . . . . . . 61
6.12. SET TIME AND DATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.13. CHECK COMMUNICATION STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.14. TCI ANALOG INPUT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.15. T
TCCI MANUAL DIGITAL OUTPUT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.16. TCI MANUAL DIGITAL INPUT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.17. DIAGNOSTIC INFORMATION DISPLAY (DID) PANEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.18. INVERTER CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.18.1. Inverter Phase Module Command and Feedback Circuitry Checks . . . . . . . . . . . . . . . . . . 70
6.19. SELF LOAD TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.19.1. Preparation for Self Load Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.19.2. Checks Prior to Self Load Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.19.3. Self Load Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

6.20. INVERTER LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6.21. FUNCTIONAL GROUND FAULT DETECTION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
ii

CONTENTS (Cont’d)
Page
7. STATISTICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.1. GENERAL DESCRIPTION AND DEFINITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.2. VIEW STATISTICAL COUNTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.3. VIEW STATISTICAL PROFILES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.4. VIEW TRUCK STAT SERIAL REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.5. RESET STATISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.6. UPLOAD STATISTICAL DATA TO A FILE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.7. PROFILE (HISTOGRAM) DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
8. DIAGNOSTIC INFORMATION DISPLAY (DID) PANEL . . . . . . . . . . . . . . . . . . . . . . 115

8.1. MODES DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
8.2. FAULTS DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
8.3. TEST DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
8.3.1. Self Load Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
8.3.2. Software Version Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
8.3.3. Link Capacitance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

8.3.4. Overspeed Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
9. EVENT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

9.1. EVENT NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
9.2. EVENT RESTRICTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
9.3. TROUBLESHOOTING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
9.4. EVENT DATA ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
9.4.1. View TCI Event Summary Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
9.4.2. View TCI Trigger Data Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
9.4.3. View TCI Data Packs Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
9.5. Re
Reset TCI Events Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
9.6. Er
Erase TCI Events Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
9.7. Event and Inverter Parameters List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
10. SPECIAL OPERATIONS AND TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

10.1. WELDING ON THE TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
10.2. M
MOOVING TRUCK WITH ONE WHEEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
10.3. VOLTAGE ATTENUATION MODULE (VAM) CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
10.4. Current Measuring Module Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
10.5. LINK CAPACITANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
11. PHASE MODUL

MODULE E AND GA GATE TE DRI DRIVERVER TRO TROUBLE UBLESHOOT SHOOTING ING
GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
11.1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
11.2. TEST/INSPECTION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
iii

CONTENTS (Cont’d)
Page
12. 17F
17FB144
B144 AND 17
17FB14
FB147
7 CIRC
CIRCUIT
UIT CA
CARD
RD TRO
TROUBLES
UBLESHOOT
HOOTING
ING
12G
.1U
. ID
INE
TRO.D
. .U.C.T. I.O.N. .. .. .. .. ..... .. .. .. .. ..... .. .. .. ..... .. .. .. ..... .. .. .. .. ..... .. .. .. ..... .. .. .. ..... .. .. .. ..... .. .. .. .. ..... .. .. .. ..... . 114499
12.2. CARD EDGE LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
12.3. Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
12.4. USING HYPE
HYPERTERM RTERMINAL INAL TO COMMUNICA COMMUNICATE TE TO 17 17FB144
FB144
AND 17FB147 BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
12.4.1. Pitfalls/Traps When Using HyperTerminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
12.4.2. Accessing HyperTerminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
13. GLOSSARY OF TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
14. SOFTWARE VERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

14.1. VERSION 19, JULY 2002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
14.2. VERSIONS INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
LIST OF TABLES
Table. No. Description Page

1. DEFA
DEFAUL
ULT
T CONFIGURA
CONFIGURATION
TION FILES AND DESCRIP
DESCRIPTIONS
TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2. GE/OEM
GE/OEM CONFIGU
CONFIGURA
RATIO
TION
N OPTI
OPTIONS
ONS AND DES
DESCRI
CRIPTI
PTIONS
ONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3. STA
STATIS
TISTIC
TICAL
AL DAT
DATA COD
CODES
ES – COUN
COUNTERS
TERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4. STA
STATIS
TISTIC
TICAL
AL DAT
DATA COD
CODES
ES – PROF
PROFILE
ILES
S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5. EVENT
EVENT CODE DESCRIP
DESCRIPTIO
TIONS
NS AND INF
INFORM
ORMA
ATION
TION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
6. TY
TYPI
PICA
CAL
L 17F
17FB1
B144
44 AND
AND 17F
17FB1
B147
47 BO
BOAR
ARD
D LED
LED PATT
TTER
ERNS
NS FOR
FOR VE
VERS
RSIO
ION
N119
9 SOF
SOFTW
TWAR
ARE
E . . . 150
150
7. GLOSS
OSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
8. VERSION 19 SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
9. SOFTWARE VERSIONS INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
iv

LIST OF ILLUSTRATIONS
Fig. No. Description Page

1. w P
PTU
TU S
ST
TARTUP SCREEN SELECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. TCI WINDOW BROWSER SCREEN SELECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. PSC WINDOW BROWSER SCREEN SELECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. w PTU
PTU TO
TOOLBOX STARTUP SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6. PSC – SERIAL LINK DATA SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7. PSC TEMPERATURES SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8. PSC LOGIC SCREENS ACCESS SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9. PSC READY MODE LOGIC SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
10. PSC PROPEL MODE LOGIC SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
11. PSC RETARD MODE LOGIC SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
12. TCI ACCEL INHIBIT LOGIC SCREEN ACCESS SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
13. TCI ACCEL INHIBIT LOGIC SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
14. CONSOLIDATED TRUCK DATA SAVE SELECTION FROM TOOLBAR. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
15. CONSOLIDATED TRUCK DATA SAVE SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
16. COMPOSITION OF A GE AC OHV CONFIGURATION FILE NAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
17. TYPICAL TRUCK CONFIGURATION SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
18. OEM TRUCK CONFIGURATION FILE TREE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
19. OPEN AC CONFIGURATION TOOL SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
20. VIEW CONFIGURATION FILES SCREEN EXAMPLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
21. PTU SCREENS CONFIGURATION BROWSER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
22. SE
SET GE / OEM OPTIONS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
23. SET WHEEL MOTOR TYPES SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
24. GE PRODUCT SERVICE DATA SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
25. TR
TRUCK SPECIFIC DATA SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
26. OVERSPEEDS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
27. OHV PTU PROGRAMMING UTILITY SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
28. PROGRAMMING THE PANEL STATUS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
29. TCI SW VERSIONS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
30. TC
T CI SET TIME AND DATE SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
31. RESET AND ERASE TCI EVENTS SELECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
32. TCI RESET STATS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
33. PSC SOFTWARE VERSIONS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
34. PTU BROWSER PSC MANUAL TEST SCREEN ACCESS SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . 53
35. PSC MANUAL TEST SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
36. PTU BROWSER TCI REAL TIME MENU ACCESS SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
37. TCI ANALOG INPUTS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
38. PTU BROWSER PSC REAL TIME MENU ACCESS SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
39. PSC ANALOG INPUT CHANNELS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
40. PSC REAL TIME DATA SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
41. PTU BROWSER TCI GAUGE CALIBRATION SCREEN ACCESS SEQUENCE. . . . . . . . . . . . . . . . . . . . 61
42. TCI GAUGE CALIBRATION SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
43. PTU BROWSER SET TIME AND DATE SCREEN ACCESS SEQUENCES. . . . . . . . . . . . . . . . . . . . . . . 63
44. SET TIME AND DATE SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
45. BROWSER TCI REAL TIME DATA SCREEN ACCESS SEQUENCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
v

LIST OF ILLUSTRATIONS (Cont’d)

46. TCI REAL TIME SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
47. TCI MANUAL TEST TRUCK STATUS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
48. TCI MANUAL TEST SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
49. PTU BROWSER PSC CONFIGURATION MENU ACCESS SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . 71
50. INVERTER PARAMETERS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
51. SELF LOAD ENGINE TEST SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
52. TC
TCI STAT_MENU SELECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
53. VIEW COUNTERS SCREEN EXAMPLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
54. MINE COUNTERS SCREEN (PSC_STATS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
55. VIEW PROFILES SCREEN EXAMPLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
56. MINE PROFILES SCREEN (PSC_STATS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
57. ST
STAT SERIAL REPORT SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
58. RESET STATS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
59. STAT PROFILE MINE RESET SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
61
60.. R
DIEDSP
DI EATNBEOLXIDQEUNETSIF
TIIC
OANTS
IOENL.E.C. T. I.O
. .N. .S.C. R
. .E. E. N
. .S. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 11
85
6
62. DID PANEL EXAMPLE – NORMAL DISPLAY (NO FAULTS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
63. DID PANEL MESSAGE EXAMPLE – FAULTS DISPLAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
64. DID PANEL MESSAGE EXAMPLE – FAULTS DISPLAY FUNCTION KEYS. . . . . . . . . . . . . . . . . . . . . . 117
65. DID PANEL MESSAGE EXAMPLE – FAULT RESET FUNCTION KEYS. . . . . . . . . . . . . . . . . . . . . . . . . 118
66. DID PANEL MESSAGE EXAMPLE – TEST DISPLAY FUNCTION KEYS. . . . . . . . . . . . . . . . . . . . . . . . . 118
67. DID PANEL MESSAGE EXAMPLE – LOAD BOX TEST FUNCTION KEYS. . . . . . . . . . . . . . . . . . . . . . . 119
68. DID PANEL MESSAGE EXAMPLE – LOAD BOX TEST DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
69. DID PANEL MESSAGE EXAMPLE – PSC SOFTWARE VERSION DATA. . . . . . . . . . . . . . . . . . . . . . . . 120
70. DID PANEL MESSAGE EXAMPLE – LINK CAPACITANCE TEST DA DATA. . . . . . . . . . . . . . . . . . . . . . . . . 121
71. DID PANEL MESSAGE EXAMPLE – OVERSPEED SETTING DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
72. TCI EVENT_MENU SCREENS ACCESS SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
73. TC
TCI EVENT SUMMARY SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
74. TCI TRIGGER DATA SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
75. TCI DATA PACKS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
76. RESET TCI EVENTS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
77. ERASE TCI EVENTS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
78. EV
E VENTS & INV PARAMS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
79. PSC CAPACITANCE TEST SCREEN ASSESS SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
80. CA
CAPACITANCE TEST SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
81. 17FB144 AN
AND 117
7FB147 BOARD TR TROUBLESHOOTING P PR ROCEDURE ((S SHEET 1 OF 2 2)). . . . . . . . . . 151
71. 17FB144 AN
AND 117
7FB147 BOARD TR TROUBLESHOOTING P PR ROCEDURE ((S SHEET 2 OF 2 2)). . . . . . . . . . 152
82. COM1 SERIAL PORT WINDOW MESSAGE FOR PROPER OPERATION. . . . . . . . . . . . . . . . . . . . . . . 153
83. HYPERTERMINAL ICON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
84. HYPERTERMINAL NEW CONNECTION WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

85. HYPERTERMINAL CONNECT TO WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
86. HYPERTERMINAL COM1 PROPERTIES WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
vi

LIST OF ILLUSTRATIONS (Cont’d)

87. HYPERTERMINAL MAIN WINDOW WHEN CONNECTED TO COM1 PORT. . . . . . . . . . . . . . . . . . . . . 157
88. HYPERTERMINAL MAIN WINDOW WHEN NOT CONNECTED TO COM1 PORT. . . . . . . . . . . . . . . . 158
89. HYPERTE
HYPERTERMI
RMINAL
NAL MAIN
MAIN WIND
WINDOW
OW AFTER
AFTER CYC CYCLIN LING G CONTROL
CONTROL POW POWER, ER,
PROGRAM INSTALLED AND RUNNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
90. HYPERTE
HYPERTERMI
RMINAL
NAL MAIN
MAIN WIND
WINDOW
OW AFTER
AFTER CYC CYCLIN LING G CONTROL
CONTROL POW POWER, ER,
PROGRAM NOT INSTALLED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
91. HYPERTERMINA
HYPERTERMINAL L MAIN WINDOW AFTER CYCLING CONTROL POWER, WITH TAB KEY KEY
HELD DOWN (INTERRUPTING BOOT–UP ROUTINE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
92. HYPERTERMINAL M MA
AIN WI
WINDOW AF AFTER E ER RASING CP CPU BO BOARD F FLLASH M ME EMORY. . . . . . . . . . . 162
93. HYPERTE
HYPERTERMI
RMINAL
NAL MAIN
MAIN WIN
WINDOW
DOW WHENWHEN BOOT– BOOT–UP UP DOEDOES S NOT RUN DUE DUE TO O OPEN
PEN
PTU SERIAL CABLE GROUND WIRE WITH THE PTU CONNECTED. . . . . . . . . . . . . . . . . . . . . . . . . . 163
vii

viii

1. OVERVIEW
This document describes the recommended truck start–up and checkout procedures at an Original Equipment
Manufacturer
Manufac turer (OEM) facility or a customer’s mine. Special programming of specific mine software requirements, soft-
ware updating, system verification procedures, and troubleshooting information are also included.
Information on the screen content and functions of the w PTU

PTU* Toolbox
Toolbox are also provided. Complete w PTU
PTU
Toolbox operational procedures are in the OHV w PTU
PTU TOOLBOX USER’S GUIDE, GEK–91712.
1.1
1.1. TOO
OOL
LS A
AND
ND TES
EST
TEEQU
QUIIPM
PMEN
ENT
T
The following are recommended tools and test equipment used in the start–up and troubleshooting of the AC Off–
Highway Vehicle (OHV) propulsion system:
1. Simpso
Simpson
nMMult
ultime
imeter
ter or Digita
Digitall M
Mult
ultime
imeter
ter
2. Megger
Megger**,
**, 0 to
to 1500
1500 volt
volt max
max.. (0–
(0–200
2000
0 Meg
Megohm
ohms)
s) @ 2 mA m
max.
ax.
3. Portable
Portable T
Test
est Un
Unit
it (PT
(PTU)
U) load
loaded
ed with GE T
Transp
ransportat
ortation
ion Syst
Systems
ems (GETS)
(GETS) OHV w PTU
PTU Toolbox software.
4. PTU cable,
cable, 9–pin RS232 communi
communication
cations
s cable with
with 1 male e
end
nd conne
connector
ctor an
and
d 1 femal
female
e end con
connector
nector
5. 1/4
1/4 in.
in. thin
thin wa
wall
ll sock
socket
et
6. Connec
Connector
tor p
pin
in extrac
extractio
tion
n and ins
insert
ertion
ion to
tooli
oling
ng as fol
follows
lows::
a. Pin Extraction,
Extraction, Amp Pt. 305183
b. Pin Inser
Insertio
tion,
n, Amp P
Pt.
t. 910
91002–
02–1
1
c. Pin Insertion,
Insertion, Amp Pt. 20
200893–2
0893–2 (f
(for
or high–de
high–density
nsity 104 pin conn
connector
ectors)
s)
d. Pin Extraction, Pei–Genesis (ITT Cannon distributor) Pt. CET–F80–16 (external contr
control
ol
e. Pin Insertion, Pei–Genesis
Pei–Genesis (ITT Cannon distributor)
distributor) Pt. CIT–F80–16
CIT–F80–16 (for external
external control cab
cabinet
inet connec-
tors)
7. Fluke 89 IIV
V or equivalent
equivalent with capaci
capacitance
tance measur
measurement
ement capabi
capability
lity..
NOTE: If a need arises

arises to disassemble one of the multi–pin
multi–pin connectors to an electronic control card pan-
el, a special thin wall socket or nut driver will be required to loosen and remove the assembly hardware.
The socket
socke t can be purchased. However, if not purchased, it is recommended that a standard 1/4 in. sock-
et or nut driver be sufficiently machined on a grinder to enable its use in performing the disassembly.
1.2..
1.2 HAN
HANDLI
DLING
NG ELE
ELECTR
CTRONI
ONIC
CPPANE
ANEL
LPPRIN
RINTED
TED CIR
CIRCUI
CUIT
TCCARD
ARDS
S
CAUTION: It is important to note that printed
printed circuit cards in the electronic contro
controll card panels are sensi-
tive to static electricity. Handling cards without proper grounding precautions could damage electronic
components mounted on them. Also, when transporting or or storing these cards, industry recommended
special static electricity–proof containers should be used.
* Trademar
Trademark
k of GE T
Transp
ransportat
ortation
ion Sys
Systems
tems
** Trademar
Trademark
k of James G. Biddl
Biddle
e Co.
1

2

2. PORTABLE TEST UNIT (PTU) DESCRIP

DESCRIPTION
TION
The PTU presently used by all GE field personnel is an IBM compatible, portable
portable PC with a hard disk, compact disc
(CD), 3.5” floppy diskette drive(s), and RS232 communicat
communicationion port. Any PC to be used with tthe
he w PTU
PTU Toolbox
should have a 500 MHz or higher processor speed and at least 128 Meg of random access
access memory (RAM). The
w PTU
PTU Toolbox is for use with software Version 19.03 (and higher) and 17FB173 Cards Version 3 (and higher).
All adjustments, setup procedures, and diagnostic troubleshooting of the truck’s control system can be made
through this PTU when loaded with the OHV w PTU
PTU Toolbox software.
NOTE: Refer to GEK–91712, OHV wPTU  User’s Guide, for complete

c omplete information on installing and using
the wPTU  Toolbox software.
Qualified GE and truck builder (OEM) specialists are able to download new software, troubleshoot system faults,
and establish the control system configuration (horsepower, etc.).
Customers’ qualified mine personnel are able to download new software, troubleshoot system faults, and set spe-
cific mine operating parameters.
2.1. w PTU
PTU ABBREVIATIONS
There may be w PTU
PTU abbreviations and terminology that are not familiar
famili ar to the user. To help with understanding
these, the w PTU
PTU Toolbox software incl
includes
udes a feature to define abbreviations on the display screen. Hold the mouse/
pointer stationary over an abbreviation and a definition window for that abbreviation will appear.
Additional terms are defined in Section 13., Glossary of Terms, TABLE 7, Glossary.
2.2. OHV w PTU

PTU TOOLBOX OVERVIEW
the wPTU  Toolbox software. Information on screen selections,
selecti ons, navigation methods, and options is
also included.
The w PTU
PTU Too
Toolbox
lbox includes the major functions described in this section.
2.2.1.
2.2.1. Rea
Real–T
l–Time
ime D
Dat
ata
a
The w PTU
PTU Toolbox can view propulsion system information such as voltages, currents, temperatures, and
speeds on a continuous basis. All propulsion system I/O can be monitored. The real–time data can be stored on the
laptop for future use.
2.2.2.
2.2.2. Sto
Stored
red Ev
Even
entt Dat
Data
a
The w PTU
PTU Toolbox
Toolbox can view and manipulate previously stored propulsion system iinformation
nformation stored through the
on–board diagnostic system.
system. Event data can be viewed in many formats including summaries or more detailed frame–
by–frame snapshots.
2.2.3.
2.2.3. Sta
Statis
tistic
tical
al Dat
Data
a
PTU Toolbox
The w PTU Toolbox can be used to view statistical information stored by the propulsion system’s on–board statis-
tical manage
m anager.
r. Numerous aspects of propulsion system operation are tracked and can be viewed on the screen as well
as downloaded to the laptop for analysis off–board.
3

2.2.4. Setting Pro

Propulsion
pulsion System Configura
Configuration
tion Options
The w PTU
PTU Toolbox
Toolbox is used by the OEM and mine personnel to generate configuration files, which can customize
propulsion system settings. Propulsion system options, pedal calibrations, and truck identification names can be set.
2.2.5.
2.2.5. Soft
Software
ware Down
Downloa
loading
ding
The w PTU
PTU Toolbox is used to download system software and configuration files to the propulsion system’s cen-
tral processing unit (CPU) cards. The propulsion system controller
controller (PSC), truck control interf
interface
ace (TCI), and Inverter
software can be downloaded in a simple one–step process.
2.2.6.
2.2.6. Dat
Data
a An
Anal
alysi
ysis
s
The w PTU
PTU To
Toolbox
olbox software contains an integrated graphing package that allows all of the system data to be
graphed for more detailed analysis. Real–time data can be graphed while on the truck or graphs can be generated
from data previously saved. All saved data can also be converted to Comma Separated V Variable
ariable (CSV) format for use
by third–party software packages such as spreadsheets.
2.2.7.
2.2.7. Syst
System
em Conf
Configur
iguratio
ation
n
Many propulsion system parameters can be modified such as setting the on–board time and date, setting test ana-
log outputs, data logger setup, and system parameter modification.
2.2.8.
2.2.8. Sel
Self–T
f–Tes
estt
The w PTU
PTU Toolbox
Toolbox software can be used to initiate or view propulsion system test information. Load–box mode,
the capacitance test, and manual self–test mode can be monitored.
2.2.9.
2.2.9. In
Integ
tegrat
rated
ed Hel
Help
p
The w PTU
PTU Toolbox
Toolbox software contains three levels of user help. Applicati
Application
on help is available for major w PTU
PTU
Toolbox functions such as logging on, saving data, graphing, etc. Screen specific help is available to help understand
the purpose and use of each screen. Mouse–over help also provides a short description of each screen screen field.
2.2
2.2.10
.10. On
One
e–S
–Sttep Do
Down
wnlo
loa
ading
All possible data to download from a truck, including event summaries, five–second data packs, and statistical data
can be downloaded with the touch of a button. This insures that the right information is gathered.
2.3. w PTU
PTU SCREEN SELECTIONS
An outline of the w PTU
PTU startup screen selections is shown in Figure 1.
NOTE: Refer to GEK–91712, OHV wPTU  User’s Guide, Sections 3.1 and 3.2 for complete information
information on
installing and starting the wPTU  Toolbox software.
The Mode Options are either Normal Mode or Offline/Training Mode. In the Normal Mode the w PTU PTU at-
tempts a connection with the target. When the connection is establis
established,
hed, the truck type and tru
truck
ck ID are obtained from
the target. (The mode options can be saved
saved in a settings file.)
NOTE: The Truck Type, Panel Type, and GE System are disabled in the Normal Mode. In the Offline/Train
Offline/T rain-
-
ing Mode, the user enters the truck type. If the AC button is selected, the user also selects the panel type.
(If the DC button is selected, the panel type is disabled.)
4 https://www.besttruckmanuals.com/

Login Screen (FIG. 4)

Mode
Normal Mode
Offline/Training Mode
LOGIN to wPTU Toolbox
Panel Type
PSC
TCI
Program Panel (goes to OHV PTU Programming Utility)
Terminal Emulator Mode (HyperTerminal)
Options (w PTU
PTU communication options)
Load Settings (select folder to load settings from)
Ac
Cfg_AC
Cfg_DC
Dc
Save Settings (select folder to save settings to)
Restore GETS Settings (restore GETS default settings)
Help (for w PTU
PTU Startup and Communication)
Exit
FIG. 1. wPTU  ST
STARTUP
ARTUP SCREEN SELECTIONS. E–44409B.
When the LOGIN to w PTU

PTU Toolbo
Toolboxx button is pressed, the entered password is verified and the user selects the
panel type, TCI or PSC.
The set of screens dedicated to TCI interaction

interaction and operation
operation is outlined in Figure 2. The BOLD typeface indicates
a menu screen, whereas normal typeface indicates a dedicated purpose screen.
The set of screens dedicated to PSC interaction and operation

operation is outlined in Figure 3. As in Fig. 2, BOLD typeface
indicates a menu screen, whereas normal typeface indicates a dedicated purpose screen.
Most of the truck startup procedures and troubleshooting procedures involve the w PTU PTU toolbox. Figure 1
through Figure 3 in this publication provide a reference to the figures associated with the various w PTU
PTU screens to
guide the user to the desired w PTU
PTU function screen.
NOTE: A brief description

description of all wPTU
wPTU  screens in contained in the Help menu. In the Menu Bar
Bar,, click on
Help –> Applications –> PTU Screen Help –> Desired Screen.
https://www.besttruckmanuals.com/ 5

PTU Screens
TCI
Normal_Operation
Real_Time (Fig. 45)
TCI – Real
Real Time
Time Data (Fig. 46)
TCI – Serial Link Data
TCI – Analog Inputs (Fig. 37)
TCI – Temperatures
Logic (Fig. 12)
Accel Inhibit
Inhibit Logic (Fig. 13)
Configuration
TCI Parameters
TCI Analog Outputs
TCI Truck Configs
TCI Software Versions
Versions
TCI Datalog Setup
Special Tasks
Event_Menu (Fig. 72)
TCI Event Summary
Summary (Fig. 73)
TCI Trigger Data (Fig. 74)
TCI Datapacks (Fig. 75)
TCI Log Events
Reset TCI
TCI Events
Events (Fig. 76)
Erase TCI
TCI Events (Fig. 77)
Stat_Menu (Fig. 52)
Stat Serial Report (Fig. 57)
View Counters (Fig. 53)
View Profiles (Fig. 55)
Reset Stats (Fig. 32)
Stat Start Date
Set Time
Time and Date (Fig. 30)
Events & Inv Params (Fig. 78)
Engine_Stopped_Tasks
Engine_Stopped_ Tasks (Fig. 41)
TCI Manual Test
Test (Fig. 48)
Gauge Calibration (Fig. 42)
Ctrl_Z_to_return_to_menu
FIG. 2. TCI WINDOW BROWSER SCREEN SELECTIONS. E–44410B.

PTU Screens
PSC
Normal_Operation
Real_Time (Fig. 38)
PSC – Real Time
Time Data (Fig. 40)
PSC – Serial Link Data
PSC – Analog Inputs (Fig. 39)
PSC – Temperatures (Fig. 7)
Inverter Info
FB173 Card Data
Logic (Fig. 8)
Ready Mode (Fig. 9)
Propel Mode (Fig. 10)
Retard Mode (Fig. 11)
Configuration
PSC Parameters
PSC Analog Outputs
FB173 analog Outputs
PSC Truck Configs
Inverter Parameters (Fig. 50)
Custom Parameters
PSC Software Versions (Fig. 33)
PSC Datalog Setup
Tests (Fig. 79)
Self Load Engine Test
Test (Fig. 51)
Temperatures
Capacitance
Capacit ance Test
Test (Fig. 80)
Special Tasks
Tasks (Fig. 43)
Event_Menu
PSC Event Summary
PSC Trigger Data
PSC Datapacks
PSC Log Events
Reset PSC Events
Erase PSC Events
Set Time
Time and Date (Fig. 44)
Events & Inv Params (Fig. 78)
Engine_Stopped_Tasks
Engine_Stopped_T asks (Fig. 34)
PSC Manual Test
Test (Fig. 35)
Ctrl_Z_to_return_to_menu
FIG. 3. PSC WINDOW

WINDOW BROWSER SCREEN SELECTIONS. E–44411B.

FIG. 4. wPTU  TOOLBOX
TOOLBOX STAR
STARTUP
TUP SCREEN. E–44340B.
2.4. w PTU
PTU STARTUP SCREEN
The w PTU
PTU Toolbox Startup screen is the initial selection screen that is displayed on the PC when the AC
PTU Toolbox is commanded (after splash screen). It is from this screen that access to all other operating menus is
w PTU
obtained (Figs. 1 through 3).
When in the Offline / Training Mode, options on this screen are selected by clicking in the selection circle ( GE
System, Panel Type, or Mode ). When in tthe
he Normal Mode (connected to a truck), these selections are performed
automatically by the w PTU
PTU Toolbox.
After entering a valid password, select any of the functions shown on the right side of the screen by clicking on the
button for the function.

the wPTU  Toolbox software. Information on screen selections,
selecti ons, navigation methods, and options is
also included.

2.5..
2.5 VIE
VIEW
WDDA
ATALO
ALOGGE
GGER
R AN
AND
D DA
DAT
TA G
GRAP
RAPH
H SC
SCREE
REENS
NS
Datalogger and Graph Data functions are contained in the GE OHV w PTU

PTU Toolbox
Toolbox (GEOHVPTU 1.0). Use
either of these functions as follows:
1. Connect
Connect the PT
PTU
U to the desired
desired p
panel,
anel, start
start the
the GE OHV PT
PTU
UTToolbox,
oolbox, and en
enter
ter a v
valid
alid passwor
password.
d.
2. Click on the AC Configuration Utility icon on the desktop or from the Start Menu go to START –> Programs
–> GEOHVPTU 1.0 –> AC Tools Datalogger (or Graph Data).
Tools –> Datalog –> Start Datalogger
3. Close th
the Datalogger or Graph Data display screen by clicking on the X in the upper right corner of the screen.
2.6.
2.6. SA
SAVI
VING
NG SC
SCRE
REEN
EN DISP
DISPLA
LAYS
YS
Any real time screen display can be saved for future viewing. Complete procedures for saving screens and data
are provided in GEK–91712, OHV w PTUPTU Toolbox User’s Guide, Section 3.5, MAIN WINDOW MENUS.
A saved screen can be replayed in both online and offline

offline modes. The screens can be saved to a file and then
then can
be replayed, converted to CSV format, or graphed (screen is saved as a binary file). The user specifies the file name
and location where the file is saved.
2.7. PASSWORDS
The ability to set passwords is provided using the Password Utility for the w PTU
PTU toolbox (Fig. 5)
5).. Refer tto
o
GEK–91712, OHV w PTU PTU Toolbox User’s Guide, Section 5, PASSWORD UTILITY for complete information on
setting
settin g passwords and password privilege levels. It is recommended tthat
hat supervisors assign passwords and privilege
levels below their own.
NOTE: On some PTUs,

PTUs, difficulty has been experienced if passwords were entered
enter ed which have zeros. The
problem was found to be caused by the PTU being in the “NumLock” mode (or “KeyPad” mode on some
PCs).. This interprets a section of the normal keypad as a numeric keypad and hence produces the wrong
PCs)
characters.
FIG. 5. START
START MENU – P
PASSWORD
ASSWORD UTILITY. E–45148.


3. SELECTED SCREEN DESCRIPTIONS AND FUNCTIONS
The following information describes selected screens and functions that are commonly used in the startup and
troubleshooti
troubl eshooting
ng of the GE OHV AC Propulsion System.
System. Sections 3.1 through 3.
3.4
4 describe screens th
that
at are contained
PTU Configuration Utility. Sections 3.5 through 3.8 describe screens and functions that are contained in
in the w PTU
the w PTU
PTU Toolbox . The propulsion system’s REST m mode
ode function is described in Section 3.
3.9.
9.
3.1.
3.1. PR
PROD
ODUC
UCT
T SE
SERV
RVIC
ICE
E DA
DAT
TA SC
SCRE
REEN
EN
This screen is used to create a tracking record for a specific truck or series of trucks (Fig. 24). This record sets a
history as to ship date, where and when the truck was placed in service, and it ties that specific truck to its operational
settings for that period of service.
From the Product Service Data screen, six possible areas may be set or changed for the specific truck or series of
trucks chosen. Only those data items which have bee
beenn authorized and activated
activated can be set or changed. Perform the
following to change the data settings:
1. Either
Either click iin
n the de
desire
sired
d box (outlin
(outlined
ed in re
red
d on the left
left of s
screen
creen)) or use the
the TAB key to scroll continuously
down through the boxes.
2. Change the set
setting
ting by deleting
deleting tthe
he exis
existing
ting set
setting
ting (p
(press
ress any
any key and ttype
ype the n
new
ew sett
setting,
ing, or s
simply
imply ty
type
pe over
the existing data).
3. Press Enter to enter the modified setting. (The box color changes from white to blue, indicating that it has been
changed and will remain blue for the present session until the file is saved.)
NOTE: To keep the changes made to the Product Service Data settings, the file must be saved.
4. Click on File and Save. Pop–up messages notify the user that the changed data has been saved, and of
offer
fer
other Save options.
3.2.
3.2. TR
TRUC
UCK
K SP
SPEC
ECIF
IFIC
IC D
DA
ATA SC
SCRE
REEN
EN
This screen is used to set the sensitivity and reactivity of the acceleration and retarding controls as desired, based
on specific operating conditions (Fig.25).
From the Truck Specific Data screen, eight possible parameters may be set or changed for the specific truck or
series of trucks chosen. In addition, the truck ID number may be entered and changed, thus choosing these settings
for a specific truck when saving the file. Only those parameters which have been authorized and activated
activated can be set
or changed. Perform the following to change the data settings
NOTE: Holding the mouse cursor over an item displays Help information for that item.
1. Either
Either click iin
n the de
desire
sired
d box (outlin
(outlined
ed in re
red
d on the left
left of s
screen
creen)) or use the
the TAB key to scroll continuously
down through the boxes.
2. Change the set
setting
ting by deleting
deleting tthe
he exis
existing
ting set
setting
ting (p
(press
ress any
any key and ttype
ype the n
new
ew sett
setting,
ing, or s
simply
imply ty
type
pe over
the existing data).
3. Press Enter to enter the modified setting. (The box color changes from white to blue, indicating that it has been
changed and will remain blue for the present session until the file is saved.)
NOTE: If a parameter is out of limits, a warning message appears. Click OK to return to the Truck Specifi
Specific
c
Data screen and correct the setting.

NOTE: To keep the changes made to the Truck Specific Data settings, the file must be saved.
4. Click on File and Save. Pop–up messages notify the user that the changed data has been saved, and offer
offer
other Save options.
The Truck Specific Data screen is used to enter the following information:
1. Percen
Percentt ret
retard
ard pedal
pedal tr
trave
avell indic
indicati
ating
ng ret
retard
ard rrequ
equest
est OF
OFF
F
 This is the percent of pot reference volts at which the control is calibrated to have zero retard request.
See section, Foot Pedal Adjustments.
2. Percen
Percentt reta
retard
rd ped
pedal
al tra
travel
vel in
indica
dicatin
ting
g reta
retard
rd req
reques
uestt FULL ON
 This is the percent of pot reference volts at which the control is calibrated to have full retard request.
3. Percen
Percentt ret
retard
ard lever
lever trav
travel
el indi
indicat
cating
ing re
retar
tard
d requ
request
est OF
OFF
F
 This is the percent of pot reference volts at which the control is calibrated to have zero retard request.
See section, Retard Lever Adjustments.
4. Percent
Percent retard
retard lever travel
travel in
indicati
dicating
ng retard
retard reques
requestt FU
FULL
LL ON
ON
 This is the percent of pot reference volts at which the control is calibrated to have full retard request.
See section, Retard Lever Adjustments.
5. Hydrau
Hydraulic
lic brak
brake
e temper
temperatu
ature
re m
mete
eterr sca
scale
le facto
factorr
 This a value from 0.0 to 1.0 that calibrates the meter reading against actual temperature.
temperature. See section,
Meter Scale Adjustments.
6. Propuls
Propulsion
ion syst
system
em temp
tempera
eratur
ture
e met
meter
er scale
scale fact
factor
or
 This a value from 0.0 to 1.0 that calibrates the meter reading against actual temperature.
temperature. See section,
Meter Scale Adjustments.
7. Percen
Percentt acc
accel
el ped
pedal
al trave
travell indicat
indicating
ing a
acce
ccell reques
requestt OFF
 This is the percent of pot reference volts at which the control is calibrated to have zero accel request.
8. Percen
Percentt acc
accel
el ped
pedal
al tra
travel
vel in
indica
dicatin
ting
g acce
accell requ
request
est FULL
FULL ON
 This is the percent of pot reference volts at which the control is calibrated to have full accel request.
9. Tru
ruck
ck iden
identi
tifi
fica
cati
tion
on numb
number
er
 This is for the mine to enter the truck identification number.
number. Truck ID shows up with the event data and
must be unique for each truck.
3.3.
.3. VI
VIEW
EW OV
OVER
ERS
SPE
PEE
EDS SC
SCRE
REE
EN
The View Overspeeds screen displays the current mine speed limit settings for the truck chosen (Fig. 26).

3.4.
3.4. SE
SET
TWWHE
HEEL
EL MO
MOT
TOR TY
TYPE
PES
SSSCR
CREE
EEN
N
A continuous record of wheel motor types used on a truck can be created by updating the settings in this screen
(Fig. 23).
This screen is used to view and change the the type of wheel motors for a specific truck or serie
series
s of trucks. A list of
possible models and their gear ratios is shown.
NOTE: Changing the wheel motor type may automatically change other default settings for the truck.
Make sure the correct wheel motor codes for this truck are entered before saving the file.
By entering the codes for the wheel motor models that are being used on this truck, two possible parameters may
be set or changed. Only those items which have been authorized and activated can be set or changed. Perform the
following to change the settings:
1. Either
Either click
click in the de
desire
sired
d box (outline
(outlined
d in red on tthe
he left o
off scre
screen)
en) or u
use
se the TAB key to toggle between the
boxes.
2. Change the set
setting
ting by deleting
deleting tthe
he exis
existing
ting set
setting
ting (p
(press
ress any
any key and ttype
ype the n
new
ew sett
setting,
ing, or s
simply
imply ty
type
pe over
the existing data).
3. Press ENTER to enter the modified setting. (The box color changes from white to blue, indicating
indicating that it has
been changed and will remain blue for the present session until the file is saved.)
4. Click on File and Save. Pop–up messages notify the user that the changed data has been saved, and of
offer
fer
other Save options.
3.5.
3.5. MO
MONI
NITO
TOR
R RE
REAL
AL TIME
TIME DA
DAT
TA
Real time data for both PSC and TCI can be viewed by using the w PTU
PTU. The PSC and TCI procedures and
screens are very similar and only require w PTU
PTU connection to the desired serial port in the operator cab.
Perform the following to monitor PSC real time data:
1. Connect the w PTU

PTU to the PSC serial port (located in the operator cab), start the GE OHV w PTU
PTU Toolbox
Toolbox,,
enter password, select PSC Panel, select appropriate truck type, and click on LOGIN to wPTU Toolbox .
2. From
From the wind
window
ow bro
brows
wser
er,, se
sele
lect
ct PTU Screens –> PSC –> Normal_Operation –> Real_Time –> PSC – Real
Time Data (Fig. 38).
3. The PSC – Real Time Data screen is now displayed (Fig. 40).
3.5.1.
3.5.1. PSC – Real Tim
Time
e Dat
Data
a Scr
Screen
een
The PSC – Real Time Data screen is separated into various sections depending upon the type of signal being
monitored.
NOTE: Refer to Section 13., TABLE

TABLE 7, Glossary, for definitions of the signal names that appear on this
and other screens.
The major sections of this screen are as follows:
1. Analogs – This section monitors the status and values of analog signals from devices such as current sensors,
voltage sensors, temperature sensors, etc.
2. Modes – This section provides information regarding the mode of operation, the direction of operation, the
commanded percent of propel or retard effort, communication status with TCI, etc.

3. Speeds – This section monitors various speed sensor signals and provides a processed truck speed indica-
tion.
NOTE: When discrete signals

signals are active, they
they are displayed inversed
inversed (highlighted).
(highlighted). This display method
is used for Digital Inputs, Digital Outputs, and Serial Link Data To and From TCI.
4. Digital Inputs (DI) – This section monitors the status of discrete input signals to PSC such as contactor posi-
tion sensors, electronic connector continuity, selector switch status, etc.
5. Digital Outputs (DO) – This section monitors the status of discrete output signals from PSC such as contactor
commands, panel enabling signals (e.g. GD1E, AFSE), indicating light control, etc.
6. Serial from TCI – This section monitors the status of discrete signals received by PSC from TCI over the PSC–
TCI serial link.
7. Serial to TCI – This section monitors the status of discrete signals provided by PSC to TCI over the PSC–TCI
serial link.
8. Inverters – This section monitors the status of various signals related to inverter operation including run status,
torque command, torque feedback, etc.
Close the PSC – Real Time Data display screen by clicking on the X in the upper right corner of the screen.
3.5.2.
3.5.2. PSC – Seri
Serial
al Li
Link
nk Da
Data
ta Sc
Screen
reen
1. From
From the wind
window
ow bro
brows
wserer,, se
sele
lect
ct PTU Screens –> PSC –> Normal_Operation –> Real_Time –> PSC – Seri-
al Link Data (Fig. 38).
2. The PSC – Serial Link Data screen is now displayed (Fig. 6).

This screen monitors the status of the serial link signals sent to and received from TCI.
3. Close the PSC – Serial Link Data display screen by clicking on the X in the upper right corner of the screen.
3.5.3.
3.5.3. PSC – Anal
Analog
og In
Inputs
puts Scre
Screen
en
1. From
From the wind
window
ow bro
brows
wser
er,, se
sele
lect
ct PTU Screens –> PSC –> Normal_Operation –> Real_Time –> PSC – Ana-
log Inputs (Fig. 38).
2. The PSC – Analog Inputs screen is now displayed (Fig. 39).

This screen monitors the status of all analog input signals to PSC.
3. Close th
the PSC – Analog Inputs display screen by clicking on the X in the upper right corner of the screen.
3.5.4.
3.5.4. PSC – T
Tempe
emperatu
ratures
res Scr
Screen
een
1. Fr
From
om the
the wind
window
ow b
bro
rows
wser
er,, sele
select
ct PTU Screens –> PSC –> Normal_Operation –> Real_Time –> PSC –
Temperatures (Fig. 38).
2. The PSC – Temperatures screen is now displayed (Fig. 7).
This screen monitors the status of various component temperatures provided either by sensors or by calcula-
tions.
3. Close the PSC – Temperatures display screen by clicking on the X in the upper right corner of the screen.

FIG. 6. PSC – SERIAL LINK DAT

DATA
A SCREEN. E–44390B.

FIG. 7. PSC TEMPERA

TEMPERATURES
TURES SCREEN. E–44392B.

3.6.
3.6. CH
CHEC
ECK
K PS
PSC
CMMOD
ODE
E LO
LOGI
GIC
C OP
OPER
ERA
ATION
TION
The PSC Logic screens can be accessed by the w PTUPTU user to check PSC Ready Mode, Propel Mode, and
Retard Mode operation. These screens display real–time ladder diagrams which show the necessar
necessaryy truck functions
and propulsion system operations that must occur in order to achieve the operating mode selected. When activated,
the various
used ladder diagramaid
as a troubleshooting functions are displayed
in diagnosing why thereversed (highlighted).
propulsion system doesIn not
this achieve
manner,athese logic screens
commanded modecan be
of op-
eration.
3.6.1.
3.6.1. Acce
Accessin
ssing
g PSC Log
Logic
ic Scr
Screen
eens
s
Perform the following to access the PSC Logic screens:
PTU Toolbox
Toolbox,,
enter password, select PSC Panel, select appropriate truck type, and click on LOGIN to w PTU
PTU Toolbox .
2. From
From tthe
he w
wind
indow
ow b
bro
rows
wser
er,, se
sele
lect
ct PTU Screens –> PSC –> Normal_Operation –> Logic (Fig. 8).
3. The PSC Logic menu of screens is now displayed. Double–click on the desired screen to display it.
3.6.
3.6.1.
1.1.
1. Re
Read
ady
yMMod
ode
eLLog
ogic
ic Sc
Scre
reen
en
1. From the Logic menu, double–click on Ready Mode to select that screen (Fig. 8).
2. The Ready Mode screen is now displayed (Fig. 9).
This screen displays the necessary requirements and the status of those requirements for the propulsion sys-
tem to achieve the Ready Mode in preparation for either a subsequent Propel Mode or
or Retard Mode of opera-
tion.
3. Close the Ready Mode display screen by clicking on the X in the upper right corner of the screen.
3.6.
3.6.1.
1.2.
2. Prop
Propel
el Mo
Mode
de Lo
Logi
gic
cSScr
cree
een
n
1. From the Logic menu, double–click on Propel Mode to select that screen (Fig. 8).
FIG. 8. PSC LOGIC SCREENS ACCESS

SEQUENCE. E–45238.

FIG. 9. PSC READY MODE LOGIC SCREEN. E–44395B.
FIG. 10. PSC PROPEL MODE LOGIC SCREEN. E–44396B.
2. The Propel Mode screen is now displayed (Fig. 10).

tem to achieve the Propel Mode of operation.

3. he Propel Mode display screen by clicking on the X in the upper right corner of the screen.
Close tth
3.6.
3.6.1.
1.3.
3. Re
Reta
tard
rd Mo
Mode
de Lo
Logi
gic
cSScr
cree
een
n
1. From the Logic menu, double–click on Retard Mode to select that screen (Fig. 8).
2. The Retard Mode screen is now displayed (Fig. 11).

tem to achieve the Retard Mode of operation.
3. Close tth
he Retard Mode display screen by clicking on the X in the upper right corner of the screen.
4. Click on the Target button to go back to the GE OHV w PTU

PTU Toolbox Login screen, close the w PTU
PTU Tool-
box, shut down the PTU, and disconnect it from the PSC serial port.
FIG. 11.
11. PSC RET
RETARD
ARD MODE LOGIC SCREEN. E–44397B.

3.7.
3.7. CH
CHEC
ECK
K TC
TCII AC
ACCE
CEL
L IN
INHI
HIBI
BIT
T LO
LOGI
GIC
C OP
OPER
ERA
ATION
TION
The TCI Accel Inhibit Logic screen can be accessed by the w PTU PTU user to check the TCI accel inhibit logic. This
screen displays real–time ladder diagrams that show the necessary truck functions and propulsion system operations
that must occur in order for an accel inhibit condition to occur. When activated, the various ladder diagram functions
are displayed reversed (highlighted). In this manner
manner,, this logic screen can be used as a troubleshooting
troubleshooting aid in diagnos-
ing why an accel inhibit condition has occurred.
3.7.1.
3.7.1. Acce
Accessin
ssing
g TCI Acce
Accell Inhibi
Inhibitt Logic Scr
Screen
een
Perform the following to access the TCI Accel Inhibit Logic screen:

PTU to the TCI serial port (located in the operator cab), start the GE OHV w PTU
PTU Toolbox
Toolbox,,
enter password, select TCI Panel, select appropriate truck type, and click on LOGIN to w PTU
PTU Toolbox .
2. Fr
From
om the
the wwind
indow
ow b
bro
rows
wser
er,, sele
select
ct PTU Screens –> TCI –> Normal_Operation –> Logic –>
–> Accel Inhibit
Logic (Fig. 12).
3. The Accel Inhibit Logic screen is now displayed (Fig. 13).
4. the Accel Inhibit Logic display screen by clicking on the X in the upper right corner of the screen.
Close th
5. Click
ick on the Target button to go back to the GE OHV w PTU
PTU Tool-
box, shut down the PTU, and disconnect it from the TCI serial port.
FIG. 12. TCI ACCEL INHIBIT LOGIC SCREEN

ACCESS SEQUENCE. E–45239.
20

FIG. 13. TCI ACCEL INHIBIT

INHIBIT LOGIC SCREEN. E–44363A.

3.8..
3.8 CON
CONSOL
SOLIDA
IDATED
TED TRU
TRUCK
CK D
DA
ATA S
SA
AVE FUN
FUNCTI
CTION
ON
To aid in getting the data from the CPU card and into the office computer, the Consolidated Truck Data Save
function has been provided in the w PTU
PTU Toolbox.
Toolbox. This function puts all the collected statistical data in a file which
can then be processed at a later time.
To upload data, do the following:

followi ng:
1. Connect the PTU to the T

TCI
CI serial
serial por
portt (located
(located in the opera
operator
tor c
cab),
ab), s
start
tart the GE OHV w PTU
PTU Toolbox,
Toolbox, enter
password, select TCI Panel, select appropriate truck type, and click on LOGIN to w PTU PTU Toolbox .
2. From the PTU Screens –> TCI screen Menu Bar, select UpLoad –> Consolidated Truck Data Save (Fig 14,
refer to GEK–91712).
NOTE: Files are normally uploaded to the following:

c:/program files/geohvptu_xx/data_ac/<tru
files/geohvptu_xx/data_ac/<truck
ck id date time>
3. Sel
Select
ect the
the type
type of repo
report
rt to
to be save
saved
d from
from the
the Reports Type list, choose a Save Directory, then click on the
Begin button to begin uploading (Fig. 15).
4. Click on Close when the uploading is complete, then click on the Target button in the screen T
Tool
ool Bar to go to
PTU startup screen.
the w PTU
5. Close th
the w PTU
PTU Toolbox,
Toolbox, shut down the PTU, and disconnect it from the TCI serial port.
NOTE: The statistical data is uploaded in the following formats:

UPL – this is a compressed binary format that is preferred when the file information will be forwarded
for GE headquarters review. This format can be converted to TXT at a later date
TXT – this is an 80 column ASCII format that is suitable for subsequent user review
CSV – this is a comma separated variable format that is suitable for import into a spreadsheet for sub-
sequent manipulation
manipulation
FIG. 14. CONSOLIDATED TRUCK DATA

DATA SAVE SELECTION FROM TOOLBAR. E–45249.
22

FIG. 15. CONSOLIDATED TRUCK DA

DATA
TA SAVE SCREEN. E–44354B.
23

3.9. REST MODE
The GE OHV AC propulsion system has a mode of operation called REST that is called for numerous times in the
truck startup procedure. In this mode of operation, power is remov
removed
ed from the DC link of the propulsion system, there-
by preventing the propulsion system from either accelerating or retarding the truck.
REST mode is commanded by applying the Parking Brake.

Brake. Applying the Parking Brake com
commands
mands the propulsion
system to go to the REST mode of operation, provided that all necessary truck operating conditions are met, such as
truck stopped. Use the REST mode indicating light and the capacitor charged lights on the main control cabinet to
confirm that the REST mode has been successfully achieved after command.
The following are the major reasons for commanding the propulsion system to REST mode:
1. It should always be done

done when shutting down a tru
truck.
ck. The propulsion
propulsion system should be pla
placed
ced in REST prior
prior tto
o
turning off the engine.
2. It should always be done

done when
when the
the op
operato
eratorr le
leaves
aves the opera
operator’s
tor’s c
cab.
ab.
3. It is often
often d
done
one when the truck
truck is e
expect
xpected
ed to id
idle
le for a
an
n exte
extended
nded pe
period
riod of time.
4. It is often done during

during the course
course o
off tru
truck
ck start–u
start–up
p and ttrouble
roubleshoot
shooting.
ing.
To bring the GE OHV AC propulsion system out of REST,REST, release the Parking Brake. Provided that truck operating
conditions are met, there will be a period of time while the propulsion system energizes the DC link and gets ready for
either accelerating and/or retarding mode truck operation.
24

4. CONFIGUR
CONFIGURAATION FILES
Config uration files are contained in the GE Truck

Configuration Truck Configuration Utility (CFG AC Vxxxx) (current
(current version). GE con-
figuration file descriptions are displayed
displayed when this utility is opened. The configuration utility is opened and files se-
lected as follows:
1. Cl
Clic
ick
k the
the mo
mous
use
e on
on the
the AC Configuration Utility icon on the desktop or from the Start Menu go to START –>
Programs –> GEOHVPTU 1xx (current version) –> AC Tools –> CFG AC Vxxxx (current version) .
2. Select the appropr
appropriate
iate GE config
configuratio
uration
n file for
for the truck (ref
(refer
er to Fi
Figure
gure 20 for ty
typical
pical View Configuration
Files screen example and refer to TABLE 1 for description of files).
3. Click
Click tthe
he on
on th
the
e fi
file
le tto
o se
select
lect it a
and
nd tthen
hen click OK to go to the PTU Screens –> Configuration Browser.
click
NOTE: A truck configuration

configuration file must be selected before any of the other uti
utility
lity menu choices can be
used except Exit.
4.1.
4.1. GE C
CON
ONFI
FIGU
GURA
RATI
TION
ON F
FIL
ILE
E NA
NAME
ME DE
DESC
SCRI
RIPT
PTIO
ION
N
Configuration
Config uration file names are established using a specific set of guidelines. Each element in a file name represe
represents
nts
a piece of information which describes the application, revision, issue date, etc. (Fig. 16).
4.2.
4.2. VIEW
VIEW TR
TRUC
UCK
KCCON
ONFI
FIGU
GURA
RATI
TION
ON SC
SCRE
REEN
EN
To view the Truck Configuration screen, from the window

wi ndow browser, select PTU Screens –> Config –> Truck
Configuration . An example of a typical Truck Configuration screen is shown in Figure 17.
Close the Truck Configuration display screen by clicking on the X in the upper right corner of the screen.
A27005A.903
A27 005 A 9 03
A27 = AC 2700 HP OHV Object Code

Propulsion System Release Minor
Version Number
A35 = AC 3500 HP OHV
Propulsion System Least Significant
Digit of Object
A15 = AC 150 Ton OHV Code Release
Propulsion System Major Version
Number
Configuration Configuration File

File Number Revision Designation
FIG. 16. COMPOSITION OF A GE AC OHV CONFIGURATION FILE NAME. E–44425B.
25

FIG. 17. TYPICAL TRUCK CONFIGURATION SCREEN. E–44348B.
26

4.3.
4.3. GE
GE/O
/OEM
EM DE
DEF
FAU
AUL
LT CON
CONFI
FIGU
GURA
RATI
TION
ON FI
FILE
LES
S
There are 15 default GE configuration

configuration files for the OHV AC propulsion
propulsion system. They are described in TABLE 1,
Default Configuration Files and Descriptions.
NOTE: Files that do not apply to 150 Ton

Ton vehicles are shaded.
One OEM configuration file should be created by the GE Product Service representative or the OEM representa-
tive for each truck type at the mine location. The GE base configuration files in T
TABLE
ABLE 1 should be used. The OEM
files should then be used to create an individual truck configuration file for each truck.
For example, if a mine location contained AC trucks of the following types:
 930E – standard with DDC 4000

 930E – standard with Cummins QSK60
The OEM configuration files would be as shown in Figure 18.
         

 

 
 
 

         
         
 
           
         
         
         
           

             
FIG. 18. OEM TRUCK CONFIGURATION FILE TREE. E–45286.
27

TABLE 1. DEFAUL
DEFAULT
T CONFIGURATION FILES AND DESCRIPTIONS
GE Standard Filename Notes Description
GE320AC – 2700 HP –– MTU Engine
1. A27005a.903 Standard Komatsu Mining Systems (KMS) 930E Standard MTU En-
gine, 31.5 Gear ratio
GE320AC – 2700 HP –– DDC 4000 ENGINE
2. A27006a.903 Standard KMS 930E Standard DDC Engine, 31.5 Gear ratio
3. a27007a.903 Oil Sands KMS 930E Oil Sands, DDC Engine 38.8 Gear ratio
4. a27008a.903 Chuqui KMS 930E DDC Engine, 31.5 Gear ratio, 10,000 Ft.
5. a27009a.903 Freeport KMS 930E DDC Engine, 31.5 Gear ratio 14,000 Ft.
6. a27010a.903 Freeport KMS 930E DDC Engine, 38.5, Gear ratio 14,000 Ft.
7. a27011a.903 Autonomous KMS 930E Autonomous, DDC, 31.5
GE320AC – 2700 HP – CUMMINS QSK60 Engine
8. a27012a.903 Standard KMS 930E Standard QSK60 Engine, 31.5 Gear ratio
9. a27013a.903 Oil Sands KMS 930E Oil Sands, QSK60 Engine, 38.8 Gear ratio
10. a27014a.903 Chuqui KMS 930E QSK60 Engine, 31.5 Gear ratio, 10,000 Ft.
11. a27015a.903 Freeport KMS 930E QSK60 Engine, 31.5 Gear ratio 14,000 Ft.
12. a27016a.903 Freeport KMS 930E QSK60 Engine, 38.8 Gear Ratio, 14,000 Ft.
13. a27017a.903 2300NHP KMS 930E QSK60 Engine, 31.5 Gear ration 2300 NHP
GE320AC – 3500HP – 930E–2SE
14. a35001a.903 Standard KMS 930E–2SE, QSK78 engine, 32.6 Gear Ratio
GE150AC – 150 Ton AC – MT3300
15. a15001a.903 Standard Unit Rig MT3300, DDC–12V engine, 28.8 Gear Ratio
28

4.4.
4.4. GE
GE/O
/OEM
EM CO
CONF
NFIG
IGUR
URA
ATION
TION OP
OPTI
TION
ONS
S
These configuration options are adjustable only by an OEM or GE representative,

representative, and can only be viewed at the
mine privilege level. Refer to Figure 22 for an example of the Set GE/OEM Options screen.
NOTE: To change GE/OEM Configuration Options requires use of the appropriate privilege level pass-
word.
For Version 19, the features shown in TABLE 2, GE/OEM Configuration Options and Descriptions, are avail-
able as GE/OEM configurable
configurable options. Default settings are noted.
NOTE: Options that do not apply to 150 T

Ton
on vehicles are shaded.
TABLE 2. GE/OEM CONFIGURATION OPTIONS AND DESCRIP

DESCRIPTIONS
TIONS
# OPTION NAME DESCRIPTION DEFAULT
1 Mine Adjustable Speed Limit Enables Overspeed Limits to be set by the Mine. Disabled
2 OEM Speed Option 1 Sets the speed at which Digital Output #5 (TCI) is ener- 10 mph
gized. The digital output signal is intended to be wired to
an external light to give indication of truck speed.
3 OEM Speed Option 2 Sets the speed at which Digital Output #6 (TCI) is ener- 25 mph
gized. The digital output signal is intended to be wired to
an external light to give indication of truck speed.
4 Engi
Engine
ne OEM
OEM sp
spee
eed
d opt
optio
ion
n Set
Sets the
the spee
speed
da att w
whi
hic
ch D
Dig
igit
ital
al Ou
Outtpu
putt #22
#22 (TCI
(TCI)) is
is e
ene
ner-
r- 1700 rpm
gized. The digital output signal can be used to drive other
OEM devices based on engine speed.
5 Du
Dump
mp Bo
Body
dy UP Sp
Spee
eed
d Lim
Limit
it Se
Sets
ts the
the s
spe
peed
ed li
limi
mitt app
appli
lied
ed to truc
truck
kwwhi
hile
le dump
dump body
body is 5 mph
UP..
UP
6 Dump Body UP Speed Limit Sets the speed limit applied to truck while dump body is 15 mph
(With Override) UP and the Override button is pressed.
7 Dump Body UP RETARD Allows full speed control (PROPEL and RETARD effort 1 = Enabled
Enable At Max Speed modulation) at the
the maximum dum
dump
p body UP speed. If dis-
abled, RETARD is not automatically applied, only PROPEL
effort is removed.
8 Motor Pressure Event En- Sets which type of axle box pressure sensor is i s present in 0 = None
able the system. Set to 1 if an analog senssensor
or is inst
installed.
alled. Set 1 = Analog
to 2 if a digital sensor
sensor is installed. Without the option
turned on, the propulsion system is unable to detect a loss l oss 2 = Digital
of cooling air to the traction motors.
9 Seco
Second
nd La
Lang
ngua
uag
ge Sup
Suppo
port
rt Enab
Enable
les
s tthe
he seco
second
nd lang
langua
uage
ge supp
suppor
ortt on
on the
the Diag
Diagno
nost
stic
ic 1 = Enabled
Information Display (DID) panel (disabled will hide the ES-
PANOL key )
29

TABLE 2. GE/OEM CONFIGURA

CONFIGURATION
TION OPTIONS AND DESCRIP
DESCRIPTIONS
TIONS (Cont’d)
# OPTION NAME DESCRIPTION DEFAULT

10 Engine C
Crranking Pr
Protection Enables the engine cranking protection strategy
strategy,, (i.e. 30 0 = Disabled
Enabled second max crank time, cooldown periods, etc.).
NOTE: This option should only be enabled on trucks
with an MTU or DDC engine. The Cummins QSK60
engine has a pre–lube feature which requires addi-
tional time and will cause engine cranking to time out.
Only QSK60 engines on trucks with KMS Truck Num-
ber 186 or greater should have this option enabled.
11 Engine Speed Limit and Deleted in Version 19 software.
High Idle Enabled
12 Hydraulic Brake Outlet Enables monitoring of the hydraulic brake outlet cooling 0 = Disabled
Temp Monitor temperatures on a KMS 930E truck.
truck. To enable this option
an updated FB160 card and the additional hydraulic sen-
sors must be installed.
13 OEM Accel Inhibit E

isnset
abletos 1,
thePSC
exteDigital
rnal OE M Ac#16
Input cel is
Inhread
ibit Lto
oginitiate
ic. If than
is faccel
lag 0 = Disabled
inhibit.
14 Engine Warm–Up Mode Enables the Engine Warm–Up Mode. 0 = Disabled
15 Engi
Engine
ne War
arm–
m–Up
Up Spee
Speed
d Engi
Engine
ne spee
speed
d sett
etting
ing to us
use
e du
duri
ring
ng Engi
Engine
ne Warm
arm–Up
–Up 1200 RPM
Mode.
16 Left Wheel M
Mo
otor T
Ty
ype Flag to ind
indica
icate the wheel m
mo
otor type of the le
left (drive
iver Configuration
side) wheel. Dependent
1 = 5GDY–85A/B
2 = 5GDY–85C
3 = 5GDY–85D
4 = 5GDY–85E
5 = 5GDY–85F
11 = 5GDY–106A
12 = 5GDY–106B
21 = GEB–23
22 = GEB–25
17 Righ
Rightt Whe
Wheel
el Motor
otor Typ
ype
e Flag
Flag to indi
indic
cate
ate tthe
he wh
whee
eell m
mot
otor
or type
ype o
off the
the ri
righ
ghtt (pa
(pass
ssen
en-- Configuration
ger side) wheel. (See selections for Option 16.) Dependent
18 RP1 Hold–In Strategy Flag to indicate which RP1 Hold–In strategy to use. The 1 = RETARD
RP1 Hold–In feature reduces the cycles during RETARD
and helps reduce both RP1 and GY–19 grid blower motor
life. The three options ar
are:
e:
0 = None
1 = RETARD Mode
2 = READY Mode
30

4.5.
4.5. SA
SAVI
VING
NG NE
NEW
WCCON
ONFI
FIGU
GURA
RATI
TION
ON FILE
FILES
S
The activated specific options define the OEM configuration and are normally saved under a file name which can
be used to uniquely identify it at a later time.
Click on File –> Save to save the new configuration (changes) as the same file and overwrite the existing configu-
ration of that file name.
Click on File –> Save As to save the new configuration (changes) as a new file and retain the existing configuration
of the original file name.
Verify that the

the desired file name is displayed. Note that the name of the file that was chosen as the valid truck
configuration is displayed automatically. A new file name is entered by typing the entire new file name. Refer back to
Figure 16 for configuration file naming conventions.
This OEM truck configuration file would be the one normally loaded at the beginning of the software download
during a truck startup. It contains the correct option settings and the default tr
truck
uck specific data.
4.6..
4.6 CON
CONFIG
FIGURA
URATI
TION
ON F
FIL
ILE
EDDEST
ESTINA
INATIO
TION
NDDIRE
IRECT
CTOR
ORY
Y
The active w PTU

PTU directory where configuration files are saved is displayed on the View Configuration Files
screen (Fig. 21) in the Destination Directory menu. All configuration files that are commanded to be saved will be
saved in this directory.
directory.
To change the configuration save directory, click on the Browse button next to the Destination Directory menu
and choose a different existing directory or type in the new full directory path name.
4.7.
4.7. CO
CONF
NFIG
IGUR
URA
ATION
TION F
FIL
ILE
E SO
SOUR
URCE
CE D
DIR
IREC
ECT
TOR
ORY
Y
The active PTU directory where configuration files are retrieved from is displayed on the View Configuration
Files screen (Fig. 21) in the Source Directory menu. All configuration files tthat
hat are available for re
retrieval
trieval and manipu-
lation are in this directory.
To change the configuration file source directory, click on the Browse button next to the Source Directory menu
and choose a different existing directory or type in the new full directory path.
31

32

5. INSTALLING AC PROPULSI
PROPULSION
ON SYSTEM SOFTW
SOFTWARE
ARE ON TRUCK
WARNING: Ensure that all mine, OEM, and GE safety procedures

procedure s are followed during truck software
installation. Ensure the truck is parked in a safe location with the Parking Brake
installation. Brakes
s applied (propulsion
(propulsion
system commanded to REST mode). Failure to do so could result in personal injury or death, as well as
equipment damage and inadvertent truck movement.
Before new software can be loaded into a truck’s propulsion system, configuration files must be created and truck–
specific parameters must be recorded. The following tasks must be comcompleted
pleted in the order listed:
1. Sele
Select
ct a G
GE
ECCon
onfi
figu
gura
rati
tion
on fi
file
le
2. Cr
Crea
eate
te a GE/
GE/OEM
OEM Opt
Optio
ions
ns fi
file
le
3. Cr
Crea
eate
te a T
Tru
ruck
ck–S
–Spe
peci
cifi
fic
c file
file
4. Save
Save exist
existing
ing truck
truck data
data (if
(if app
applic
licable
able))
5. Prog
Progra
ram
m th
the
e TC
TCI,
I, PSC
PSC,, an
and
d In
Inve
vert
rter
ers
s
6. Checko
Checkout
ut to ver
verify
ify prop
proper
er softw
software
are inst
install
allati
ation
on
NOTE: The OEM filefile only needs to

to be created one
one time. A truck–specifi
truck–specific
c file must be created for each
individual truck.
truck. The full installation
installation process takes approximately
approximately 40 minutes.
5.1.
5.1. SE
SELE
LECT
CTIN
ING
GTTHE
HE GE C
CON
ONFI
FIGU
GURA
RATI
TION
ON F
FIL
ILE
E
NOTE: An appropriate
appropriate level password is required to enter
enter the Configur
Configuration
ation tool.
1. Choose
Choose the app
approp
ropria
riate
te G
GE
E confi
configur
gurati
ation
on ffile.
ile.
a. Cl
Clic
ick
k on
on tthe
he AC Configuration Utility icon on the desktop or from the Start Menu go to START –> Pro-
grams –> GEOHVPTU xx (current version) –> AC Tools –> CFG AC Vxxxx (current version) (Fig. 19).
b. Select the appropriate
appropriate GE configuration file for the truck (see Figure 20 for typical View Configuration
Files screen example and refer to Section 4., TABLE 1, Default Configuration Files and Descriptions
for description of files).
c. Click on
on the file
file to s
selec
electt it an
and
d then c
click
lick OK to go to the PTU Screens –> Configuration Browser (Fig.
21).
2. Set the
the ap
appro
propri
priate
ate GE/O
GE/OEM
EM optio
options
ns fo
forr the m
mine
ine lo
locat
cation
ion..
a. Fr
From
om the PTU Screens –> Configuration Browser, select Set GE/OEM Options.
b. Set the appropriate
appropriate options
options for th
the
e specific m
mine
ine envir
environment
onment.. Section 4., TABLE 2, GE/OEM Configura-
tion Options and Descriptions, describes the available options and Figure 22 shows an example screen.
c. Press ENTER after modifying any field and click on the X in the upper right corner of the screen to close it.
d. Fr
From
om the
the PTU Screens –> Configuration Browser, select Set Wheel Motor Types.
e. Enter the number corresponding
corresponding to the left and rright
ight wheel m
motor
otor types
types,, then click on the X in the upper right
corner of the screen to close it
i t (Fig. 23).
33

f. From th
the PTU Screens –> Configuration Browser, select Product Service Data (Fig. 24). Set the fol-
lowing items in this screen and press ENTER after each change/entry:
(1) Mine
ine Na
Name
me
(2
(2)) GE Mi
Mine
ne Code
Code
(3
(3)) Mo
Mode
dell o
off Tru
ruck
ck
g. Name the OEMOEM configuration
configuration fil
file
e according
according to the ffollowing
ollowing conv
convention
ention and save the ffile.
ile. Replace the first
three digits of the GE configuration file with “OEM”.
“OEM”. For example, OEM006a.903 would
would be the OEM config-
uration file that is derived from GE configuration file
fil e A27006a.903.
FIG. 19. OPEN AC CONFIGURA

CONFIGURATION
TION TOOL SEQUENCE. E–44345A.
34

FIG. 20. VIEW CONFIGURATION FILES SCREEN EXAMPLE. E–44347A.
35

FIG. 21. PTU SCREENS CONFIGURATION

BROWSER. E–45203.
FIG. 22. SET GE / OEM OPTIONS SCREEN. E–44351B.

36
FIG. 23. SET WHEEL M

MOTOR
OTOR TYPES SCREEN. E–45204.
FIG. 24. GE PRODUCT SERVICE DA

DATA
TA SCREEN. E–44352B.
37
5.2..
5.2 CRE
CREA
ATE THE TRU
TRUCK/
CK/MIN
MINE
ECCONF
ONFIGU
IGURA
RATIO
TION
NFFILE
ILE
1. Determine and record
record the pedal,
pedal, poten
potentiome
tiometer
ter (po
(pot),
t), and lev
lever
er adjust
adjustment
ment par
paramet
ameters
ers acco
according
rding to th
the
e proce-
dure described in Section 6.8., PEDAL, POT, AND LEVER ADJUSTMENT CHECKS .
2. Determine
Determine and rec
record
ord the gau
gauge
ge calibr
calibration
ation ad
adjustm
justment
ent para
paramete
meters
rs according
according to the pro
procedur
cedure
e descri
described
bed in
Section 6.9., GAUGE CALIBRATION CHECKS.
3. Click
ick on the AC Configuration Utility icon on the desktop or from the Start Menu go to START –> Programs
–> GEOHVPTU 1xx (current
(current version) –> AC Tools version) (Fig. 19).
Tools –> CFG AC Vxxxx (current version)
4. Select 0 – Select a truck configuration, and choose the appropriate GE/OEM configuration file (created pre-
viously,, Figure 20).
viously
5. Click on the OK button to go to the PTU Screens –> Configuration Browser.
6. From the PTU Screens –> Configuration Browser, select Product Service Data.
7. The Product Service Data screen is now displayed (Fig. 24).
8. Set the fol
follow
lowing
ing iitem
tems
s in thi
this
s sc
scree
reen
n and
and pr
press
ess ENTER after each change/entry:
a. OEM Truc
Truck
k Seria
Seriall Number
Number
b. OEM
OEM Shi
ShippD
Dat
atee
c. In Serv
Servic
ice
eDDat
ate
e
9. Close th
the Product Service Data screen by clicking on the X in the upper right corner of the screen.
10.
10. Fr
From
om the
the PTU Screens –> Configuration Browser, select Truck Specific Data.
11. The Truck Specific Data screen is now displayed (Fig. 25).
12. Enter the Pedal
Pedal and Gauge settings
settings that wer
were
e calculated pr
previously
eviously and tthe
he truck num
number
ber and pres
press
s ENTER
after each change/entry.
change/entry.
FIG. 25.
25. TRUCK SPECIFIC DATA
DATA SCREEN. E–45206.
38
FIG. 26. OVERSPEEDS SCREEN. E–44561A.
13
13.. Cl
Clos
ose
e tthe
he Truck Specific Data screen by clicking on the X in the upper right corner of the screen.
14. If mine–setta
mine–settable
ble speed limit is enabled,
enabled, set the proper
proper overs
overspeeds
peeds as follo
follows:
ws:
a. Fr
From
om the PTU Screens –> Configuration Browser, select Overspeeds.
b. The View Overspeeds screen is now displayed (Fig. 26).
c. Enter the desired
desired oversp
overspeed
eed va
values
lues an
and
d pres
press
s ENTER after each change/entry.
d. Cl
Clos
ose
e the
the View Overspeeds screen by clicking on the X in the upper right corner of the screen.
15. Save the
the file tto
o a truck–spe
truck–specific
cific ffile
ile nam
name;
e; acw1903.xxx is
is recommended, where xxx is
is the truck number.
5.3. SA
SAVE
VE EXIST
EXISTING
ING TRUCK DA
DAT
TA (Not Appl
Applicab
icable
le to New Truck
rucks)
s)
For trucks that have had previous software installed, the truck’s event and statistical data should be saved prior to
downloading new software. (Also refer to Section 3.8., Consolidated Truck Data Save Function .)
1. Connect the PTU to the TCI

TCI seri
serial
al por
portt (loc
(located
ated in the opera
operator
tor c
cab),
ab), start
start the GE OHV w PTU
PTU Toolbox,
Toolbox, enter
also refer to GEK–91712).
3. Select All Reports, choose a Save Directory, then click on the Begin button to begin uploading (Fig. 15).
4. Click on Close when the uploading is complete.
PTU Tool-
39
5.4. PROGRAM TCI

1. Connect the PTU to the TTCI
CI serial
serial por
portt (located
operator
tor c
cab),
ab), s
start
PTU Toolbox,
Toolbox, enter
password, and click on the Program Panel button (Fig. 4).
2. From the OHV PTU Toolbox Programming Utility screen, under AC Drive Systems, ALL, select TCI (Fig.
27).
3. Select the
the ap
appro
propri
priate
ate c
conf
onfigu
igurat
ration
ion ffile
ile ffrom
rom the Select Configuration File menu by clicking Browse to open
the menu, then clicking on the desired file.
4. Click
ick on
on the Begin Download button to start downloading and automatically open the Programming the Pan-
el status screen
screen (Fig. 28).
28). The OHV w PTU
PTU Toolbox Programming Utility will automatically download the TCI
with the latest TCI software and the chosen configuration file.
NOTE: It may be necessary
necessa ry to cycle control power in order to download. Do so by turning the Control
Power Switch or Keyswitch OFF, then back ON.
5. Click
ick on the Exit button when the download is complete to go back to the OHV w PTU
PTU Programming Utility
screen.
6. Click on the Exit button again to go back to the GE OHV w PTU
PTU Toolbox Login screen, then close the
w PTU
PTU Toolbox,
FIG. 27. OHV PTU PROGRAMMING UTILITY

UTILITY SCREEN. E–44355B.
40
5.5. PROGRAM PSC

1. Connect the PT
PTU
U to the PSC ser
serial
ial por
portt (loc
(located
ated in
in the op
operat
erator
or ca
cab),
b), st
start
art tthe
he GE OH
OHV
V w PTU
PTU Toolbox, enter
password, and click on the Program Panel button (Fig. 4).
2. From the OHV w PTU
PTU Toolbox Programming Utility screen, under AC Drive Systems, ALL, select PSC
(Fig. 27).
3. Select the
the ap
appro
propri
priate
ate c
conf
onfigu
igurat
ration
ion ffile
ile ffrom
rom the Select Configuration File menu by clicking Browse to open
the menu, then clicking on the desired file.
4. Click o n the Begin Download button to start downloading and automatically open the Programming the Pan-
on
el status screen (Fig. 28). The OHV w PTU
PTU Toolbox
Toolbox Programming Utility will automatically dow
download
nload the PSC
with the latest PSC software and the chosen configuration file.

5. Click o
on
n tth
he Exit button when the download is complete to go back to the OHV w PTU
screen.
6. Click on the Exit button again to go back to the GE OHV w PTU
PTU Toolbox,
w PTU Toolbox, shut down the PTU, and disconnect it from the PSC serial port.
FIG. 28. PROGRAMMING THE PANEL ST

STATUS
ATUS SCREEN. E–44356B.
41
5.6. PROGRAM IIN

NVERTERS
1. Apply the Parking
Parking Brake (prop
(propulsion
ulsion syste
system
m com
commanded
manded to REST
REST mode).
mode).
2. Open the
the con
control
trol cabine
cabinett door and se
sett the Groun
Ground
d Fault Cutou
Cutoutt switch
switch to the CUTOUT (Down) position.
3. Check
Check the
the link c
char
harged
ged light
lights
s and ve
verif
rify
y the lilink
nk is di
disch
scharg
arged.
ed.
4. Connect the PTU to
to the CNG (Inve
(Inverter
rter #
#1)
1) serial
serial por
portt loca
located
ted ins
inside
ide the group
group,, start
PTU T
Tool
ool--
box, enter password, and click on the Program Panel button (Fig. 4).
5. From the OHV w PTU
PTU Toolbox Programming Utility screen, under AC Drive Systems, GE150AC, select
Inverter (Fig. 27).
6. Select the app
approp
ropria
riate
te objec
objectt fi
file
le from
from the
the Select Object File menu by clicking Browse to open the menu, then
clicking on the desired file.
7. Click
ick on
on the Begin Download button to start downloading and automatically open the Programming the Pan-
el status screen (Fig. 28). The OHV w PTU
PTU Toolbox Programming Utility will automatically download the
connected inverter with the latest software and the chosen object file.
fil e.

8. Click
ick on the Exit button when the download is complete to go back to the OHV w PTU
screen.
9. Click on
on the Exit button again to go back to the GE OHV w PTU
PTU Toolbox Login screen and disconnect the
w PTU
PTU from the CNG (Inverter #1) serial port.
10.
10. Co
Conn
nnec
ectt th
the
e w PTU
PTU to the CNH (Inverter #2) serial port and repeat steps 5 through 9 of this procedure.
11. Cl
Clic
ick
k on th
the
e Exit button again to go back to the GE OHV w PTU
w PTU
PTU Toolbox,
Toolbox, shut down the PTU, and disconnect it from the CNH (Inverter #2) serial port.
12. Set the
the Ground Fault Cutout
Cutout s
switch
witch ba
back
ck to tthe
he NORMAL (Up) position and close the control cabinet door.
5.7. CHECKOUT
Verify proper software installation by performing the following

follow ing steps:
1. Connect the PTU to the T TCI
CI serial
serial por
portt (located
operator
tor c
cab),
ab), s
start
PTU Toolbox,
Toolbox, enter
2. From
From th
the
e wi
wind
ndow
ow bro
brows
wser
er,, sel
selec
ectt PTU Screens –> TCI –> Normal_Operation –> Configuration –> TCI SW
Versions.
3. The TCI SW Versions screen is now displayed (Fig. 29).
4. Verify
Verify tthe
he following
following version
version informat
information
ion o
on
n the
the dis
display
play screen
screen::
TCI VER: {current version}
TRUCK TYPE: {150 ton}
TRUCK ID
ID: {current ttrruck}
5. Close th
the TCI SW Versions display screen by clicking on the X in the upper right corner of the screen.
6. Verif
Verify
y the TCI’
TCI’s
s tim
time
e is se
sett cor
correc
rectly
tly a
as
s fol
follows
lows::
a. From the window browse
browser,
r, select PTU Screens –> TCI –> Special_Tasks –> Set Time and Date .
42
FIG. 29. TCI SW VERSIONS SCREEN. E–45255.
FIG. 30. TCI SET TIME AND DA

DATE
TE SCREEN. E–44380A.
b. The Set Time and Date screen is now displayed (Fig. 30)

c. Correct
Correct the date
date and time
time setti
setting
ng as necessary
necessary an
and
d click on SET CLOCK to enter the changes.
d. Cl
Clos
ose
e the
the Set Time and Date display screen by clicking on the X in the upper right corner of the screen.
7. Reset
Reset tthe
he TCI’
TCI’s
s event
event inform
informati
ation
on as
as fo
follo
llows:
ws: (Fi
(Fig.
g. 31)
a. From the windo
window
w brow
browser
ser,, sele
select
ct PTU Screens –> TCI –> Special_Tasks –> Event_Menu –> Reset TCI
Events .
b. The RESET the Active TCI Events selection screen is now displayed.
c. Clic
Click
k on Yes to reset the events and close the screen.
d. From the windo

window
w brow
browser
ser,, sele
select
ct PTU Screens –> TCI –> Special_Tasks –> Event_Menu –> Erase TCI
Events .
e. The ERASE the Stored TCI Events selection screen is now displayed.
43
FIG. 31. RESET AND ERASE TCI EVENTS SELECTIONS. E–44367A.
f. Click on Yes to erase the events and close the screen.
NOTE: The following step must

must be performed the first time V19 or higher software is install
installed
ed due to the
additional counter categories
categories (yesterday
(yesterday,, last month, this month).
month). This step is not required for subse-
quent software downloads.
8. Reset the TCI’s
TCI’s Statistical
Statistical Infor
Information
mation as follow
follows:
s: (Fig. 32)
a. From the windo
window
w browser
browser,, select
select PTU Screens –> TCI –> Special_Tasks –> Stat_Menu –> Reset Stats.
Special_Tasks
b. The Reset Stats screen is now displayed.

c. Click
Click on tthe
he selec
selectio
tion
n box ffor
or Reset ALL <GE AND MINES> Statistics and click on Yes in the question
window that pops up.
d. Cl
Clos
ose
e the
the Reset Stats display screen by clicking on the X in the upper right corner of the screen.
PTU Toolbox Login screen and disconnect the
w PTU
PTU from the TCI serial port.
10.
10. Co
Conn
nnec
ectt th
the w PTU
PTU to the PSC serial port (located in the operator cab) and click on LOGIN to w PTU
PTU T
Tool
ool--
box.
FIG. 32. TCI RESET STA

STATS
TS SCREEN. E–45208.
44
FIG. 33. PSC SOFTWARE VERSIONS SCREEN. E–45209.
11. From the window brows

browser
er,, se
select
lect PTU Screens –> PSC –> Normal_Operation –> Configuration –> PSC
SW Versions.
12. The PSC SW Versions screen is now displayed (Fig. 33).

13. Verify
Verify the follo
following
wing version
version inform
information
ation on the display
display scree
screen:
n:
PSC V
VE
ER: {current ve
version}
TRUCK
TRUCK TYPE:
TYPE: {150 ton}
ton}
TRUCK ID
ID: {current tr
truck}
INV1 VE
VER: {current ve
version}
INV2 VER: {current version}
14
14.. Cl
Clos
ose
e tthe
he PSC SW Versions display screen by clicking on the X in the upper right corner of the screen.
15. Reset the PSC’s
PSC’s event inform
information
ation as
as follo
follows:
ws: (simi
(similar
lar to F
Fig.
ig. 31)
a. From the window browse
browser,
r, select PTU Screens –> PSC –> Special_Tasks –> Event_Menu –> Reset
PSC Events .
b. The RESET the Active PSC Events selection screen is now displayed.
c. Clic
Click
k on Yes to reset the events and close the screen.
d. From the window browse
browser,
r, select PTU Screens –> PSC –> Special_Tasks –> Event_Menu –> Erase
PSC Events.
e. The ERASE the Stored PSC Events selection screen is now displayed.
f. Click on Yes to erase the events and close the screen.
16. Verify NO events
events ar
are
e logge
logged
d on the DID
DID pane
panell (ref
(refer
er to Section 8.2., Faults Display, for DID panel faults infor-
mation).
17. From the window brows
browser
er,, sele
select
ct PTU Screens –> PSC –> Normal_Operations –> Real_Time –> PSC –
Real Time Data.
45
19. On tth
he PSC – Real Time Data screen, verify the following:
 ACCEL–SEL = 0.00 with the Accel Pedal at rest
 ACCEL–SEL = 1.00 with the Accel Pedal fully engaged
NOTE: The following verifications require
require that Service Brake/Wheel Lock/Load Brake is not applied
applied.. En-
sure the Parking Brake is applied (propulsion
(propulsion system commanded to REST mode) and it is safe to re-
move the service brakes.
 RETRD–SEL = 0.00 with the Retard Pedal and Lever (if equipped) set to the OFF position.
 RETRD–SEL = 1.0 with the Retard Pedal at FULL. (If a 1 pedal system, ensure the service brake is not
entered)
 RETRD–SEL = 1.0 with the Retard Lever (if equipped) at FULL and the retard pedal OFF.
20. Apply the Parking Brake if not done previously (propulsion system commanded to REST mode).
21. Using the appropri
appropriate
ate mine procedure
procedures,
s, start tthe
he diesel engin
engine.
e.
22. Verify the System
System M
Mode
ode is REST on the DI
DID
D panel (refe
(referr to Section 8.1., Modes Display, for DID panel modes
information).
23. Release the Parking Brake (propulsion system exits REST mode) and verify the Syst
System
em Mode changes to
TEST, then READY within one minute.
24. With the brakes applied, move the Direction Selector
Selector handle tto
o FORWARD and verify torqu
torque
e is present o
on
n each
inverter (TQCMD1, TQCMD2, and TRQFB1, TRQFB2) shown on the PSC – Real Time Data screen.
25. Verify
Verify no EVENTS are logged
logged as
as follo
follows:
ws:
a. From the window browser,
browser, select PTU Screens –> PSC –> Special_Tasks –> Event_Menu –> PSC
Event Summary.
b. The PSC Event Summary screen is now displayed on top of the PSC – Real Time Data screen.
c. Verify that
that no EVENTS
EVENTS are
are logged,
logged, the
then
n clos
close
e the PSC Events Summary display screen by clicking on the
X in the upper right corner of the screen.
26. Return
Return the Directi
Direction
on Selector
Selector handle
handle to NEUTRAL
NEUTRAL..
27. Using the appropri
appropriate
ate mine procedures
procedures,, initiate Load
Load Box operatio
operation PTU or DID panel (for
n through the w PTU
w PTU
PTU, from the window browser, select PTU Screens –> PSC –> Normal_Operation –> Tests –> Self
Load Engine Test). (Fig. 51) (Refer to Section 8.3., Tests Display, for DID panel tests information.)
28. Maintain Load Box operation
operation at full engin
engine
e RPM for two minutes and
and verify that ful
fulll horsepower is develop
developed.
ed.
29. Verify
Verify no EVEN
EVENTS
TS log during
during Load B
Box
ox Mode a
as
s follows
follows::
a. From the window browser,
browser, select PTU Screens –> PSC –> Special_Tasks –> Event_Menu –> PSC
Event Summary.
b. The PSC Event Summary screen is now displayed (on top of the Self Load Engine Test screen if using
w PTU
PTU for test).
c. Verify that
that no EVENTS
EVENTS are
are logged,
logged, the
then
n clos
close
e the PSC Events Summary display screen by clicking on the
30.
30. Ex
Exit
it Load
Load Bo
Box.
x.
31.
31. Cl
Clic
ickk on
on the
the Target button to go back to the GE OHV w PTU
PTU Toolbox Login screen, then close the w PTU
PTU
Toolbox, shut down the PTU, and disconnect it from the PSC serial port.
46
6. TRUCK ST
STARTUP
ARTUP PROCEDU
PROCEDURES
RES
6.1..
6.1 CIR
CIRCUI
CUIT
T CON
CONTIN
TINUIT
UITY
Y AND RE
RESIS
SIST
TANC
ANCE
E CHE
CHECKS
CKS A
AND
ND AD
ADJUS
JUSTME
TMENTS
NTS
The following circuit continuity and resistance checks and adjustments should be performed prior to energizing the
AC OHV propulsion system equipment. These procedures require the use of a volt–ohmmeter (VOM) that is set for
resistance measurements.
WARNING: Electric shock can cause serious or fatal injury

injury.. To avoid such injury, personnel should take
and observe proper precautions when making system adjustment or performing system or component
electrical tests. For resistance checks, this should include, bu
butt not be limited to, ensuring that all equip-
ment is deenergized, including energy storage components such as capacitors.
6.1.1.
6.1.1. VOM Circ
Circuit
uit and C
Compo
omponen
nentt Check
Checks
s
If a VOM reading is significantly different from the value listed in the following chart, consult the system schematic
and inspect the affected circuit, checking connections and replacing components and wiring as required.
Ci
Circ
rcui
uit/
t/Co
Comp
mpon
onen
entt VO
VOM
M Conn
Connec
ecti
tion
on VOM Positive Lead VOM Negative VOM Reading in
Note Connection Lead Connection Ohms (Approx.)
DC Link DC+ Link Bus Bar Cabinet Ground 2800
(Top Bus Bar)
NOTE: If GNDB1 (ground block) is disconnected from the Ground Resistor Panel
(GRR), both the DC+ and DC– resistance to ground readings will be higher.
DC– Link Bus Bar Cabinet Ground 2800
(Bus Below DC+)
VOM on R1 Scale to DC+ Link Bus Bar DC– Link Bus Bar Infinity
avoid charging ca-
pacitors
VOM on R1 Scale to DC– Link Bus Bar DC+ Link Bus Bar 5.5
avoid charging ca-
pacitors
47
6.2
6.2. MEG
EGGE
GER
RTTES
EST
TFFOR
OR GR
GROU
OUND
NDS
S
WARNING: Electric shock can cause serious or fatal injury. To avoid such injury, personnel
personnel should take
and observe proper precautions when making system adjustment or performing system or component
electrical tests.
CAUTION: Check the polarity of the suppression modu

modulesles and diodes across all coils: relays, contactors
and reverser. If any are reversed, output channels on the digital input/outp
input/output
ut cards can be damaged dur-
ing attempts at energization.
energization.
CAUTION: A bell ringer must not be used for

for wiring checks; use an ohmmeter or lig
light
ht continuit
continuity
y checker.
CAUTION: Before removing any of the cards in the 17FL375 electronics panel, turn battery power to the
control system OFF.
The control equipment circuitry is classified in two major categories: main power circuit and alternator field control.
Both circuit categories must be separately prepared for meggering.
NOTE: Do not put shorting wire on terminal boards.
6.2.1.
6.2.1. Prep
Preparat
aration
ion For Meg
Megger
ger T
Test
est
Perform the following procedures to prepare the circuit categories for meggering
meggering by either removing wiring connec-
tions, insulating or jumpering, as indicated by the instructions. Use shorting wire for jumpering procedures, however,
however,
be careful not to short devices to ground or to the wrong devices.
1. Place both Inverter Cutout s

switches,
witches, located in
inside
side the main cont
control
rol cabine
cabinet,
t, in th
the
e CUTOUT (down) po
position.
sition.
2. Ensure
Ensure that the
the Parking
Parking Bra
Brake
ke is app
applied
lied (p
(propuls
ropulsion
ion sys
system
tem command
commanded
ed to RE
REST
ST mode).
mode).
3. Place the
the GF Cutout
Cutout switch,
switch, located
located inside tthe
he main contr
control
ol cabi
cabinet,
net, in the CUT
CUTOUT
OUT (down)
(down) posi
position.
tion.
4. Di
Disc
scon
onne
nect
ct Batt
Batter
ery
y Pow
Power
er..
5. Disconnect
Disconnect the
the round
round power plug fr
from
om the top of each ph
phase
ase an
and
d chopp
chopper
er mod
module:
ule:
PM1A+, PM1A–, PM1B+, PM1B–, PM1C+, PM1C–, PM2A+, PM2A–, PM2B+,

PM2B+, PM2B–, PM2C+, PM2C–,
CM1, CM2
6. Discon
Disconnec
nectt al
alll 17F
17FL37
L375pa
5panel
nel 104 pin
pin c
conn
onnect
ectors
ors..
7. Install
Install a jumper
jumper between
between the po
positive
sitive and neg
negative
ative DC link b
bus
us bar
bars
s in the contr
control
ol cabin
cabinet.
et.
8. Disconnect the CCLR1

CCLR1 and CCLR2
CCLR2 con
connect
nectors
ors wh
which
ich are
are locat
located
ed on the power
power c
cabin
abinet
et cei
ceiling
ling ab
above
ove the
the AFSE
panel.
9. Discon
Disconnec
nectt the c
circ
ircula
ularr con
connec
nector
tors
s fro
from
m all V
VAM’
AM’s.
s.
10. Remove
Remove all wires from g
ground
round bloc
block
k GNDB which is locat
located
ed to the left of the
the AFSE.
11. Remove the GF contactor arc chute and install a jumper between the main contactor tips
tips on GF
GF..
48
6.2.2.
6.2.2. Megg
Megger
er T
Test
est Pr
Proced
ocedure
ure
CAUTION: To prevent equipment damage, use a 1500 V DC max. @ 2 mA max. megger only.
6.
6.2.
2.2.
2.1.
1. Ma
Main
in Po
Pow
wer Ci
Circ
rcui
uitt
1. Instal
Installl a jump
jumper
er from
from th
the
e GF main
main cont
contact
actor
or ti
tip
p to gr
groun
ound.
d.
2. Connect a meg
megger
ger between
between th
the
e power circuit DC positive
positive bus bar and ground. Tur
Turn
n on the megger and tes
testt at
1500 V DC max. The reading should be approxim
approximately
ately one megohm.
3. Turn
Turn off
off a
and
nd discon
disconnec
nectt the
the meg
megger
ger..
6.2.
6.2.2.
2.2.
2. Al
Alte
tern
rnat
ator
or F
Fie
ield
ld Circ
Circui
uitt
1. Remove
Remove tthe
he jumper
jumper ffrom
rom the
the GF ma
main
in conta
contacto
ctorr tip tto
o gro
ground
und..
2. Install
Install a jumper
jumper from the po
power
wer c
circuit
ircuit DC posi
positive
tive bus
bus bar to gr
ground.
ound.
3. Connect a megg
megger
er between
between tthe
he GF mmain
ain con
contact
tactor
or tip and gr
ground.
ound. Turn
Turn on tthe
he meg
megger
ger an
and
d test at 150
1500
0 V DC
max. The reading should be infinity.
4. Turn
Turn off
off a
and
nd discon
disconnec
nectt the
the meg
megger
ger..
This concludes the megger test. If any readings were below one megohm, an insulation fault is present and must
be located and repaired. If the reading is low because of moisture, the machine must be dried out by heating it for
severall hours. Heat can be applied using several methods: 1) heat lamp, 2) hair dr
severa dryer,
yer, 3) pass
passing
ing a controlled current
through the winding for a specific time period, 4) removing the machine from the truck and baking it in an oven at a
controlled temperature for a specific time period.
After repairs are made, remegger that circuit to ensure a good quality repair. To aid in finding a fault, see Section
6.3., Troubleshooting For Grounds.
6.2.3.
6.2.3. Res
Resto
tore
re Cir
Circu
cuitr
itry
y
If no faults were found, remove shorting wires and reconnect all wires and cables previously disconnected for this
test as follows:
1. Remove
Remove the jum
jumper
per wire
wire betwe
between
en the GF c
contact
ontactor
or tips and rein
reinstall
stall tthe
he GF contacto
contactorr arc c
chute.
hute.
2. Remove
Remove the jumper
jumper wire from the po
power
wer ci
circuit
rcuit DC positive
positive b
bus
us bar
bar to g
ground.
round.
3. Remove
Remove the jumper wire b
betwee
etween
n the positi
positive
ve and negat
negative
ive DC link bus
bus bars.
bars.
4. Reconn
Reconnect
ect all
all wires p
prev
reviou
iously
sly re
remov
moved
ed from
from grou
ground
nd block
block GND
GNDB.
B.
5. Re
Reco
conn
nnec
ectt the
the VAM con
conne
nect
ctor
ors.
s.
6. Reconn
Reconnect
ect the CCL
CCLR1
R1 and CCLR
CCLR2
2cconn
onnect
ectors
ors..
7. Reconn
Reconnect
ect all 17FL37
17FL375
5ppane
anell conn
connect
ectors
ors..
8. Reconn
Reconnect
ect the
the power
power plug
plug to all
all pha
phase
se an
and
d cho
choppe
pperr mod
module
ules.
s.
9. Re
Reco
conn
nnec
ectt Ba
Batt
tter
ery
y Po
Powe
werr.
49
6.3.
6.3. TR
TROU
OUBL
BLES
ESHO
HOOT
OTIN
ING
GFFOR
OR GR
GROU
OUND
NDS
S
1. Give
Give the tru
truck
ck a quick
quick visual
visual insp
inspect
ection
ion loo
lookin
king
g for the
the followin
following:
g:
a. IMoisture,
IMoistur e, oil, or debris in or on motorized wheels, alternat
alternator,
or, grid resistors, main control c
cabinet,
abinet, and power
cables
b. Any wire or metal
metal that might
might be tou
touching
ching exp
exposed
osed con
connectio
nections
ns
c. IFraye
IFrayed
d or rubbing
rubbing cab
cables
les
2. If the visual
visual inspection
inspection do
does
es not locate
locate th
the
e cause
cause,, follo
follow
w the meg
megger
ger procedur
procedures
es to iso
isolate
late th
the
e ground to one of
the three major loops.
3. Once the ground

ground has been isolated
isolated tto
o a particular
particular lloop,
oop, that
that loop should b
be
e broke
broken
n down in
into
to smaller
smaller sections
sections
and remeggered.
NOTE: Refer to the overall system schematic to obtain the most co

convenient
nvenient points for subsection isola-
tion.
NOTE: This subdividing of the grounded section should continue until the ground is isolated in a
particular cable or piece of
of equipment. Appropriate
Appropriate measures can then be taken.
4. If the ground
ground occu
occurs
rs in a motorize
motorized
d wheel or a
altern
lternator
ator,, the unit should b
be
e check
checked
ed by rem
removing
oving al
alll connec
connections
tions
and remeggering.
5. Perform
Perform a vigo
vigorous
rous inspect
inspection
ion of th
the
e unit fo
following
llowing tthe
he guide
guidelines
lines of the insp
inspectio
ection
n made in s
step
tep 1.
6. If no reason for
for the ground
ground can be det
determi
ermined,
ned, or if th
the
e proble
problem
m cannot b
be
e corre
corrected,
cted, rremova
emovall of the unit fo
forr
repair at an authorized shop will
w ill be necessary.
7. If the ground
ground is iisolated
solated tto
o the Dynamic
Dynamic Re
Retarding
tarding Assembly,
Assembly, disconnect
disconnect all cables lea
leading
ding to it and rremegger
emegger
the Dynamic Retarding Assembly.
Assembly.
8. If the ground
ground is still
still present,
present, tho
thorough
roughly
ly inspec
inspectt the Dynamic
Dynamic Ret
Retarding
arding As
Assembly
sembly ffor
or any obvious
obvious pro
problems
blems
such as frayed or rubbing cables and water or debris inside the Dynamic Retarding Assembly.
9. If the inspect
inspection
ion does n
not
ot locate
locate the cau
cause,
se, isol
isolate
ate the two
two halve
halves
s of the Dyn
Dynamic
amic Ret
Retarding
arding A
Assemb
ssembly
ly and
remegger to localize the ground to one side or the other.
10. On trucks equipped

equipped with a blown Dynamic Retarding
Retarding Asse
Assembly
mbly,, if the ground occur
occurs
s on the blower motor
motor side,
disconnect the motor and check for grounds in the unit once again.
11. If the ground is still

still present in the
the Dynamic Retar
Retarding
ding Assembly
Assembly,, it will be nece
necessary
ssary to disco
disconnect
nnect each res
resistor
istor
section until the grounded section is found.
50
6.4.
6.4. LO
LOW
W VO
VOL
LTAG
AGE
E PO
POWE
WER
R SU
SUPP
PPL
LY CH
CHEC
ECKS
KS
6.4.1.
6.4.1. Prep
Preparat
aration
ion for Po
Power
wer Sup
Supply
ply Che
Check
ck
1. Remove
Remove the 50 amp cont
control
rol circ
circuit
uit system
system fuse
fuse (BA
(BATFU)
TFU) loc
located
ated ne
near
ar the bott
bottom
om of the powe
powerr secti
section
on of the
control cabinet behind the center door.

2. Disconnect all the 17FL375 panel ca
cards
rds ffrom
rom their
their ba
backplane
ckplane connecto
connectors.
rs. Ver
Verify
ify th
that
at all panel connector
connectors
s are
connected.
6.4.2.
6.4.2. Powe
Powerr Supp
Supply
ly V
Volta
oltage
ge Checks
NOTE: If during the course of these checks a reading is significantly different from the expected value,
consult the system schematics, inspect the circuit, check connections,
connections, and replace components as re-
quired.
6.4.2.1. Battery
1. Turn
Turn the tru
truck
ck battery
battery switch ON and
and check po
polarity
larity o
off the battery
battery volt
voltage
age at th
the
e locatio
location
n where BATFU
BATFU was
removed. The BABATFU
TFU input side should read positive, and the other side should read negative (battery com-
mon).
2. Turn
Turn th
the
e truck
truck battery
battery s
switch
witch OFF a
and
nd rreinsta
einstallll the
the BATFU
BATFU fu
fuse.
se.
3. Turn the ba
batter
ttery
y switch
switches
es and the key
key switc
switch
h in the oper
operator’s
ator’s ca
cab
b ON to enabl
enable
e contr
control
ol power av
availab
ailability
ility to the
the
AC OHV propulsion system.
6.
6.4.
4.2.
2.2.
2. Sy
Syst
stem
em P
Pow
ower
er S
Sup
uppl
ply
y
1. Turn
Turn the Co
Control
ntrol Power Switch
Switch ((CPS,
CPS, located
located in
inside
side of the ma
main
in cont
control
rol cab
cabinet)
inet) O
ON.
N.
2. On the FH41
FH41 Powe
Powerr Supply (locat
(located
ed in con
control
trol ar
area
ea of ca
cabinet
binet be
below
low the IICP
CP panel
panel),
), view tthe
he gree
green
n statu
status
s
LEDs. Verify that all five LEDs (+15V, –15V, +5V, +24V, –24V) are illuminated.
NOTE: Sensor Power Supply (SPS) and FB127 have been replaced by the FH41 Power Supply.
6.
6.4.
4.2.
2.3.
3. DID
DID Po
Powe
werr Su
Supp
pply
ly
Check that the DID panel is illuminated.
6.5.
.5. PS
PSC
C AN
AND
DTTCI
CI CAR
ARD
DCCHE
HEC
CKS
1. Tur
urn
n the
the CPS
CPS OFF
OFF..
2. Verify that all ICP panel (17FL375) cards are properly ins
installed
talled and connected to the backplane of the panel.
3. Locate the FAT1

FAT1 LEDs at the bot
bottom
tom of the
the PSC CPU card
card (17F
(17FB147)
B147) and the TCI CPCPU
U card (1
(17FB144)
7FB144) near
near
the card extractor for each. Turn the CPS ON and observe that both LEDs on both cards should initially turn ON
and then turn OFF.
OFF. If any LED remains illuminated, it may indicate either a bad CPU card or a problem with the
+5V power
pow er supply in that panel. Determine the possible faulty card by turning the CPS OFF,
OFF, removing one card
from the affected panel, and turning the CPS ON until the faulty card is identified.
CAUTION: Always turn the Control Power Switch (CPS) OFF before either removing or installing control
cards in electronic panels.
panels. Failure to do so will result
result in card and/or panpanel
el equipment damag
damage.
e.
51
6.6.
6.6. LO
LOAD
AD A
AC
C OH
OHV
V PR
PROP
OPUL
ULSI
SION
ON S
SYS
YSTE
TEM
M SO
SOFT
FTW
WAR
ARE
E
Refer to section, INSTALLING AC PROPULSION SYSTEM SOFTWARE ON TRUCK, for details regarding
downloading of software into the AC OHV propulsion system.
6.7..
6.7 PSC MAN
MANUAL
UAL DIG
DIGIT
ITAL
AL IINPU
NPUT/O
T/OUTP
UTPUT
UT T
TEST
EST PRO
PROCED
CEDURE
URES
S
Perform the following procedure to manually check certain PSC–controlled outputs and PSC–monitored inputs to
verify proper wiring and component operation:

Parking Brake (prop
(propulsion
ulsion syste
system
m com
commanded
manded to REST
REST mode).
mode).
2. Ensu
Ensure
re en
engi
gine
ne is OFF
OFF.
3. Connect the PTU

PTU to th
the
e PSC serial
serial p
port
ort (locat
(located
ed in the
the oper
operator
ator cab)
cab),, sta
start
rt th
the
e GE OHV w PTU
password, select PSC Panel, select appropriate truck type, and click on LOGIN to w PTU PTU Toolbox .
4. From
From the
the w
win
indo
dow
w brow
browse
serr, se
sele
lect
ct PTU Screens –> PSC –> Engine_Stopped_Tasks –> PSC Manual Test
(Fig. 34).
5. The PSC Manual Test screen is now displayed (Fig. 35).
FIG. 34. PTU

SCREEN BROWSER
ACCESS PSC MANUAL
SEQUENCE. TEST
E–45224.
52
FIG. 35. PSC MANUAL TEST SCREEN. E–44402A.
53
6. Perfor
Perform
m the ffollo
ollowin
wing
g digi
digital
tal o
outp
utput
ut ch
check
ecks
s from the PSC Manual Test screen:
from
a. In the Toggle Digital Outputs (TDO) section of the screen, click on GF to highlight it. Verify that the GF
contactorr picks up and that GFFB is highlighted in the Digital Input (DI) section of this screen. Click on GF
contacto
again in the TDO section of the screen to deenergize GF.
b. In the TDO section of the screen, click on GFR to highlight it. Ver

Verify
ify (visually) that the GFR contactor picks
up. Click on GFR again in the TDO section of the screen to deenergize GFR.
c. In tth
he TDO section of the screen, click on RP1 to highligh
highlightt it. Verify that the RP1 contactor picks up and that
RP1FB is highlighted in the DI section of this screen. Click on RP1 again in the TDO section of the screen to
deenergize RP1.
d. In tth
he TDO section of the screen, click on CPRL to highlig
highlight
ht it. Verify that after turning the CPS OFF
OFF,, control
power remains applied to to the AC OHV propulsion s system.
ystem. Turn CPS back to the ON position. position. Click on
CPRL again in the TDO section of the screen to deenergize CPRL.
e. In the TDO section of the screen, click on AFSE to highlight it. Verify that ther
there
e is 24V DC to ground on the
AFSEF1L and AFSEF2L wires on the AFSE terminal
terminal boards. Click on AFSE again in the TDO section of
the screen to deenergize AFSE.
NOTE: All LEDs, the Inverter #1 Cutout switch, and the Inverter #2 Cutout switch are not present in the
17KG527B1 (or later) configurations of the 150 Ton AC Control Group.
NOTE: Steps 6f thru 6i and step 7 apply only to the 17KG527A1 Control Group.
f. In the TDO section of the screen, click on SYSRUN to highlight it. Verify that the CONTROL SYSTEM
OKAY LED inside the control area is illuminated. Click on SYSRUN again in the TDO section of the screen
to deenergize SYSRUN.
g. In the TDO section of the screen, click on TEST to highlight it. Verify that the TEST MODE LED inside the
control area is illuminated. Click on TEST again in the TDO section of the screen to deenergize TEST.
h. In the TDO section of the screen, click on REST to highlight it. Verify that the REST MODE LED inside the
control area is illuminated. Click on REST again in the TDO section of the screen to deenergize REST.
i. In the TDO section of the screen, click on SYSFLT to highlight it. Verify that the SYSTEM FAULT LED on
the side of the main
main control cabinet is illuminated. Click on SYSFLT again in the TDO section of the screen
to deenergize SYSFLT.
54
7. Pe
Perf
rfor
orm
m the
the foll
follow
owing Digital Input checks:
ing
a. With the Keyswit

Keyswitch
ch and the CPS
CPS ON, veri
verify
fy that the
the follow
following
ing Digital Inputs are illuminated: KEYSW,
CPSFB, CNFB, CNIFB, CNXFB, and GFNCO .
b. Move
shouldthe
be Inverter
Ihighlighted.
nverter #1 Cutout
Move switch, located
this switch backinside
to the the control position,
NORMAL area, to INV1CO
the CUT
CUTOUT
OUT position,
should INV1CO
then turn OFF.
c. Move the Inverter

Inverter #2 Cutout
Cutout switch, loca
located
ted inside the control
control area to the CUTOU
CUTOUT
T position, INV2CO
should be highlighted. Move this switch back to the NORMAL position, INV2CO should then turn OFF.
d. Di
Digit
gital
al In
Inpu
putt BRAKEKON will be highlighted if the Service Brake is engaged, otherwise, it will be off.
e. Cl
Clos
ose
e the
the PSC Manual Test display screen by clicking on the X in the upper right corner of the screen.

PTU Tool-
55
6.8..
6.8 PED
PEDAL,
AL, POT
POT,, AND LE
LEVER
VER ADJ
ADJUST
USTMEN
MENT
T CHE
CHECKS
CKS
The following procedure is for recording and checking the AC OHV propulsion system adjustments for the specific
truck foot pedals and the retard speed control pot:
1. Remove
Remove ccont
ontrol
rol powe
powerr fro
from
m the AACC OHV pr propu
opulsi
lsion
on syste
system.
m.
2. Connect the PTU to the TTCI
CI serial
serial por
portt (located
operator
tor c
cab),
ab), s
start
PTU Toolbox,
Toolbox, enter
3. Apply
Apply co
contr
ntrol
ol power
power to
to the AC OHV propul
propulsio
sion
n system
system..
4. From
From th
the
e wi
wind
ndow
ow bro
brows
wser
er,, sel
selec
ectt PTU Screens –> TCI –> Normal_Operation –> Real_Time –> TCI Analog
Inputs (Fig. 36).
5. The TCI Analog Inputs screen is now displayed (Fig. 37). Perform the following from this screen:
a. Record
Record the value
value for
for POTREF (typical value is 10.8 V).
b. Record
Record the value
value for
for ACCEL PEDAL with the pedal FULL OFF (typical value is 1.6 V).
c. Record
Record the value
value for ACCEL PEDAL with the pedal FULL ON (typical value is 8.5 V).
d. Pull up on the Retard

Retard Speed Cont
Control
rol Switch, and record
record the value for RSC POT with the knob turned FULLY
CLOCKWISE (typical value is 0.1 V).
e. Record
Record the
the valu
value
e for
for RSC POT with the knob turned FULLY COUNTER–CLOCKWISE (typical value is 10.7
V).
f. Close the TCI Analog Inputs display screen by clicking on the X in the upper right corner of the screen.
6. Click
PTU Tool-
7. Connect the PTU
PTU to th
the
e PSC serial
serial p
port
ort (locat
(located
ed in the
the oper
operator
ator cab)
cab),, sta
start
rt th
the
e GE OHV w PTU
FIG. 36. PTU BROWSER TCI REAL TIME MENU

56
FIG. 37. TCI ANALOG INPUTS SCREEN. E–44361A.
57
FIG. 38. PTU BROWSER PSC REAL TIME

MENU ACCESS SEQUENCE. E–44388B.
8. From
From the wind
window
ow bro
brows
wser
er,, se
sele
lect
ct PTU Screens –> PSC –> Normal_Operation –> Real_Time –> PSC – Ana-
log Inputs (Fig. 38).
9. The PSC – Analog Inputs screen is now displayed (Fig. 39). Perform the following from this screen:
a. Record
Record the value
value for
for RETARD PEDAL with the pedal FULL OFF (typical value is 3.3 V).
b. Record
Record the value
value for
for RETARD PEDAL with the pedal FULL ON (typical value is 9.5 V).
c. Cl
Clos
ose
e the PSC – Analog Inputs display screen by clicking on the X in the upper right corner of the screen.
10. From the window

window browser
browser,, se
select
lect PTU Screens –> PSC –> Normal_Operation –> Real_Time –> PSC – Real
(Fig. 38).
Time Data
11. The PSC – Real Time Data screen is now displayed (Fig. 40). Perform the following from this screen:
a. With accel
accel pe
pedal
dal FULL
FULLY
Y RELEASED
RELEASED,, verif
verify
y that ACCEL–SEL = 0.00.
If it is not, calculate the accel pedal off percent by dividing the recorded value in step 5b of this procedure by
the recorded value in step 5a of this procedure (ACCEL PEDAL OFF VOLTS VOLTS / POT REF). Record this as
the new CC_ACCEL_PEDAL_OFF_PCNT parameter value.
b. With accel
accel pe
pedal
dal FULL
FULLY
Y PRESSED, v
verify
erify tthat
hat ACCEL–SEL = 1.00.
If it is not, calculate the accel pedal on percent by dividing the recorded value in step 5c of this procedure by
the recorded value in step 5a of this procedure (ACCEL PEDAL ON VOLTS / POT REF). Record this as the
new CC_ACCEL_PEDAL_ON_PCNT parameter value.
c. With retard
retard pedal FU
FULL
LLY
Y RELEASED,
RELEASED, verify
verify that RETRD–SEL = 0.00.
If it is not, calculate the retard pedal off percent by dividing the recorded value in step 9a of this procedure by
the recorded value in step 5a of this procedure (RETARD
(RETARD PEDAL OFF VOLTS / POT REF). Record this as
the new CC_RETARD_PEDAL_OFF_PCNT https://www.besttruckmanuals.com/
parameter value.
58
d. With retard
retard pedal FU
FULL
LLY
Y PRESSED,
PRESSED, verify that RETRD–SEL = 1.00.
verify
If it is not, calculate the retard
retard pedal on percent by dividing the recorded value in step 9b of this procedure by
the recorded value in step 5a of this procedure (RETARD
(RETARD PEDAL ON VOLTS / POT REF). Record this as
the new CC_RETARD_PEDAL_ON_PCNT parameter value.
e. With retard speed control knob PULLED OUT and knob turned FULL
FULLY
Y CLOCKWISE (turned to TURTLE
icon), verify that RETSPD = 0.0.
f. With retard
retard spee
speed d control
control knob PULLE
PULLED
D OUT and knob tur
turned
ned FULL
FULLY
Y CLOCKWISE (t
(turned
urned to RABBI
RABBIT
T
icon), verify that RETSPD > 36.
g. Cl
Clos
ose
e th
the PSC – Real Time Data display screen by clicking on the X in the upper right corner of the screen.
12. Clic
Click
k on the
PTU Tool-
FIG. 39. PSC ANALOG INPUT CHANNELS SCREEN. E–44391A.

59
FIG. 40. PSC REAL TIME DA

DATA
TA SCREEN. E–44389B.
60
FIG. 41. PTU BROWSER TCI GAUGE

CALIBRATION SCREEN ACCESS SEQUENCE.
E–44382A.
6.9.
6.9. GA
GAUG
UGE
E CA
CALI
LIBR
BRA
ATION
TION CH
CHEC
ECKS
KS
The following is
i s the procedure for recording and checking the AC OHV propulsion system adjustments for the spe-
cific truck gauges:

TCI seri
serial
al por
portt (loc
(located
ated in the opera
operator
tor c
cab),
ab), start
PTU Toolbox,
Toolbox, enter
2. Fro
Fromm tthe
he win
window
dow bro
browse
wserr, sele
select
ct PTU Screens –> TCI –> Engine_Stopped_Tasks –> Gauge Calibration
(Fig. 41).
3. The TCI Gauge Calibration screen is now displayed (Fig. 42).
4. Enter
Enter a test
test sp
speed
eed o
off 10
10,, 20
20,, 30
30,, or 40 M
MPH
PH in the Type a Truck Speed box and verify that the dashboard
speedometer displays that reading.
Adjust speeds for best overall reading. If the speedometer does not adjust, use the adjustment screw on the
back of the speedometer to calibrate its reading.
6.10.. CONF
6.10 CONFIGURA
IGURATION
TION CH
CHANGES
ANGES DU
DUE
E TO CAL
CALIBRA
IBRATION
TION C
CHECKS
HECKS
If, after performing the pedal, lever, pot, and gauge calibration checks, one or more configuration parameters re-
quired change, then do the following:
1. Change ththe
e af
affected
fected truck sp
specific
ecific parameter
parameters
s in the ttruck
ruck spec
specific
ific conf
configuratio
iguration
n file fo
following
llowing the procedur
procedure
e in
the section, CREATE THE TRUCK/MINE CONFIGURATION FILE.
2. Download the software

software into
into the AC OHV pr
propulsion
opulsion system
system following tthose
hose sam
same
e proced
procedures
ures in the sect
sections,
ions,
PROGRAM TCI and PROGRAM PSC.
3. After the
the new conf
configurat
iguration
ion has been download
downloaded,
ed, repe
repeat
at the pr
previous
evious ca
calibrat
libration
ion checks
checks to verify
verify the new
settings.
61
FIG. 42. TCI GAUGE CALIBRATION

CALIBRATION SCREEN. E–44384A.
62
FIG. 43. PTU BROWSER SET TIME AND DATE

DATE SCREEN ACCESS SEQUENCES. E–44366A.
6.1
6.11. SE
SET
TTTIM
IME
EAAND
ND D
DA
ATE
The date and time must be set for the PSC and TCI. The procedure for setting the date and time on either is the
same. In order to set the date and time on a particular computer, you mus
mustt be connected to the appropriate port in the
operator’s cab. The following procedure is for TCI,
TCI, but it is the same
same except for connecting to and selecting PSC:
NOTE: The PSC time is kept synchronized to the TCI time during operation. The TCI is considered the
master clock.

TCI seri
serial
al por
portt (loc
(located
ated in the opera
operator
tor c
cab),
ab), start
PTU Toolbox,
Toolbox, enter
2. From
From the
the w
win
indo
dow
w br
brow
owse
serr, se
sele
lect
ct PTU Screens –> TCI –> Special_Tasks –> Set Time and Date (Fig. 43).
3. The Set Time and Date screen is now displayed (Fig. 44).
4. If the
the da
date
te an
and
d tim
time
eddis
ispla
playe
yed
d in
in The CURRENT date and time: line are correct, click on the X in the upper right
corner of the screen to exit without changing.
5. On the Set Time and Date screen (Fig. 44), click within the applicable window ( DAY, MONTH, YEAR, HOUR,
MINUTES ) and enter the new values, or highlight the existing values in the applicable window and enter the
new values.
6. Repeat
Repeat ste
step
p 4 for each
each of the fiv
five
e windo
windows.
ws.
7. Click o
on
n the SET CLOCK button at the desired moment for the clock to be set to the time settings entered to set
the new values into memory
8. Ver
erif
ify
y th
that
at tthe
he tim
time
e disp
displa
laye
yed
d in The NEW Date and time: line is correct. If not, repeat steps 5 through 7.
9. Close tth
he Set Time and Date display screen by clicking on the X in the upper right corner of the screen.
10.
10. Cl
Clic
ick
k on the Target button to go back to the GE OHV w PTU
on the PTU Toolbox Login screen, close the w PTU
PTU Tool-
box, shut down the PTU, and https://www.besttruckmanuals.com/
disconnect it from the TCI serial port.
63
FIG. 44. SET TI

TIME
ME AND DA
DATE
TE SCREEN. E–45227.
64
FIG. 45. BROWSER TCI REAL TIME DA

DATA
TA
SCREEN ACCESS SEQUENCES. E–45231.
6.12.. CHECK COMMU

6.12 COMMUNICA
NICATION
TION ST
STA
ATUS
The following procedure verifies that PSC and TCI are communicating properly with each other.

TCI seri
serial
al por
portt (loc
(located
ated in the opera
operator
tor c
cab),
ab), start
PTU Toolbox,
Toolbox, enter
2. From
From tthe
he w
wind
indow
ow b
bro
rows
wser
er,, se
select PTU Screens –> TCI –> Normal_Operation –> Real_Time –> TCI Real
lect
3. The TCI Real Time Data screen is now displayed (Fig. 46).
4. In the Modes section of the TCI Real Time Data screen, verify that COMMLINK is OK.
If not, check wiring between PSC and TCI. If that does not uncover the problem, remove power from the control
system, then reapply power.
power. If that does not clear the problem, then rep
replace
lace one CPU card at a time in order to
determine the faulty card.
5. Close tth
he TCI Real Time Data display screen by clicking on the X in the upper right corner of the screen.
PTU Tool-
7. Connect the PT
PTU
U to the PSC ser
serial
ial por
portt (loc
(located
ated in
in the op
operat
erator
or ca
cab),
b), st
start
art tthe
he GE OH
OHV
V w PTU
8. From
From the wind
window
ow bro
brows
wser
er,, se
sele
lect
10. In th
the Modes section of the PSC – Real Time Data screen, verify that COMMLINK is OK.
If not, check wiring between PSC and TCI. If that does not uncover the problem, remove power from the control
system, then reapply power.
power. If that does not clear the problem, then rep
replace
lace one CPU card at a time in order to
determine the faulty card. https://www.besttruckmanuals.com/
65
FIG. 46. TCI REAL TIME SCREEN. E–44359A.
11. Cl
Clos
ose
e the
the PSC – Real Time Data display screen by clicking on the X in the upper right corner of the screen.
12.
12. Cl
Clic
ick
k on
on tthe
he Target button to go back to the GE OHV w PTU PTU Tool-
66
6.13
6.13.. TC
TCII AN
ANAL
ALOG
OG IINP
NPUT
UT C
CHE
HECK
CKS
S
The following procedure verifies proper TCI analog input signal levels and measurements. If any of the following
measurements differ significantly from their
their nominal values, check the signal source and wiring interface tto
o TCI. If
those check out OK, replace the TCI analog input card.

PTU Toolbox
Toolbox,,
PTU Toolbox .
2. From
From th
the
e wind
window
ow bro
brows
wser
er,, selectt PTU Screens –> TCI –> Normal_Operation –> Real_Time –> TCI Analog
selec
Inputs (Fig. 45).
3. The TCI Analog Inputs screen is now displayed (Fig. 37).
4. Check th
the POTREF reading on the TCI Analog Inputs screen. It should be within 1.0 V of the measurement at
TB18 (wire number 2CS121 WHT15PV) in the OEM cab shifter console. (Typical value is 15.0 V V.)
.)
5. Measure the vo
voltage
ltage at
at TB18 (w
(wire
ire num
number
ber 10VDC)
10VDC) in th
the
e OEM elec
electroni
tronics
cs cabinet
cabinet containing
containing TC
TCII shifter
shifter con-
sole.. This processed Pot Reference voltage should be approximately 1 11.0
1.0 V
V..
6. Check the CONTROL BATT reading on the TCI Analog Inputs screen. It should be within 1.0 V of the mea-
surement on the battery fuse panel located inside the control cabinet.
7. Check tth
he GROUND reading on the TCI Analog Inputs screen. It should be 0.0 V
V..
8. Check tth
he GAIN CHECK reading on the TCI Analog Inputs screen. It should be 10.0 V
V..
9. Close the PSC – Real Time Data display screen by clicking on the X in the upper right corner of the screen.
10.
10. Cl
Clic
ick
k on
on the
PTU Tool-
6.14.
6.14. TCI MA
MANUA
NUAL
L DIGI
DIGIT
TAL OU
OUTPU
TPUT
T CHE
CHECKS
CKS
The following procedure verifies the proper wiring and component operation of certain discrete devices controlled
by TCI. If any of the following devices do not respond as indicated, check the device and the TCI wiring interface
interface with
that device. If those check out OK, replace the appropriate TCI digital I/O card (consult system schematic to identify
proper card).

TCI seri
serial
al por
portt (loc
(located
ated in the opera
operator
tor c
cab),
ab), start
PTU Toolbox,
Toolbox, enter
2. From
From tthe
he win
windo
dow
w brow
browse
serr, se
sele
lect
ct PTU Screens –> TCI –> Engine_Stopped_Tasks –> TCI Manual Test
(Fig. 41).
CAUTION: Do not proceed with TCI Manual Test checks until the Parking Brake is applied (propulsion
system commanded to REST mode).
3. The TCI Manual Test Truck Status screen will request truck status; verify correct status and click on OK to
proceed (Fig. 47).
4. The TCI Manual Test screen is now displayed (Fig. 48).
67
FIG. 47. TCI MANUAL TEST TRUCK STATUS

STATUS SCREEN. E–45232.
FIG. 48. TCI MANUAL TEST SCREEN. E–44383B.
68
6.15.
6.15. TCI M
MANU
ANUAL
AL DI
DIGIT
GITAL
AL IN
INPUT
PUT C
CHEC
HECKS
KS
The following procedure verifies the proper wiring between TCI and certain truck devices. If TCI does not respond
as indicated, check the device and the TCI wiring interface
interface with that device. If those check out OK, replace the
the ap-
propriate TCI digital I/O card (consult system schematic to identify proper card).
For each digital input check, verify that the input on the Digital Inputs section of the TCI Manual Test screen (Fig.
48) responds appropriately to the input from the external truck device.
1. When the
the Eng
Engine
ine System
System Cont
Controll
roller
er iss
issues
ues an “Engin
“Engine
e Caution”
Caution” o
outpu
utput,
t, ENGCAUTION should be displayed.
2. When the Engine

Engine System Contr
Controller
oller issues an “Engine
“Engine Wa
Warning”
rning” output
output,, ENGWARN should be displayed.
3. When the
the Parking
Parking Brake
Brake is appli
applied
ed (propuls
(propulsion
ion system
system co
comman
mmanded
ded to RE
REST
ST mod
mode),
e), PRKBRKFDBK should
be displayed.
4. When
When the Rese
Resett swi
switch
tch in
in the o
oper
perato
atorr cab iis
s act
actuat
uated,
ed, RESET should be displayed.
5. When the Dir

Directio
ection
n Selector
Selector hand
handle
le in the opera
operator
tor ca
cab
b is mov
moved
ed to th
the
e FORW
FORWARD
ARD posi
position,
tion, FORREQ should
be displayed.
6. When the
the Direction
Direction Selector handle in the operator
operator cab is mov
moved
ed to the REV
REVERSE
ERSE po
position,
sition, REVREQ should
be displayed.
7. When
When any
any En
Engine
gine Shutdo
Shutdown
wn s
swit
witch
ch is actuated, ENGKILL should be displayed.
actuated,
8. When
When the Data
Data Stor
Store
e swit
switch
ch in tthe
he op
opera
erator
tor cab
cab is ac
activ
tivate
ated,
d, DATASTORE should be displayed.
9. Wh
When
en tthe
he du
dump
mp body
body is down
down,, BODYDWN should be displayed. When the dum
dump
p body is raised, BODYDWN
should no longer be displayed.
10. When
When the Load
Load Bra
Brake
ke is applie
applied,
d, LDBRK should be displayed.
11. When the

the Keyswitch
Keyswitch is moved
moved to the Engi
Engine
ne Start positi
position,
on, ENGSTRTREQ should be displayed.
12. When the

the Retar
Retard
d Speed Control
Control s
switch
witch is p
pulled
ulled up
up,, RSC should be displayed.
13. When the Payload

Payload Meter indicates
indicates that tthe
he truck payl
payload
oad is 25% of capa
capacity
city or great
greater,
er, FULL–PAYLD should
be displayed.
NOTE: The axle box pressure switch should be adjusted to trip when the axle box door is open 4” at
normal blower speed.
14. When the axle

axle b
box
ox is pressurized
pressurized,, AXLEP should be displayed.
15. When the

the Control
Control Power Switch
Switch is turned
turned to tthe
he ON posit
position,
ion, CONTROLON should be displayed.
16
16.. Cl
Clos
ose
e tthe
he TCI Manual Test display screen by clicking on the X in the upper right corner of the screen.
17.
17. Cl
Clic
ick
k on
on the
PTU Tool-
69
6.16.. DIAGN
6.16 DIAGNOSTI
OSTIC
C INFORMA
INFORMATION
TION DISP
DISPLA
LAY
Y (DID) P
PANEL
ANEL CHEC
CHECK
K
View the DID panel (17FM558).

(17FM558). The cursor to the right of the event code should appear to spin. If it does not,
remove power from the control system
system,, then reapply power. If the problem persists,
persists, check that TCI is powered
powered up and
operational and check the wiring
wiring between TCI and the DID panel. If no problem is found there, first
first replace the TCI
CPU card and then replace the DID panel until the problem is corrected.
6.17
6.17.. INVE
INVERT
RTER
ER CH
CHEC
ECKS
KS
The following procedures verify proper

proper inverter control operation.
operation. If a particular step of this procedure cannot be
completed properly, replace the 17FB172 Inverter Control card(s).
NOTE: The HyperT

HyperTerminal*
erminal* application program must be running
running on the wPTU  before applying control
power to the propulsion
propulsion system. If not, the Inverter Fault
Fault Checks procedure cannot be performed. Refer
to Section 12.4., Using HyperTerminal To Communicate To 17FB144 and 17FB147 Boards, for additional
information on using the HyperTerminal application program.
NOTE: If at any time, the wPTU  locks up or does not operate in an expected manner, type “X” three
times in succession.
6.17.1
6.17.1.. Inv
Invert
erter
er Pha
Phase
se Mo
Modu
dule
le Co
Comma
mmand
nd an
and
d Fee
Feedb
dbac
ack
k Circ
Circuit
uitry
ry Ch
Check
ecks
s
1. Connect the PTU
PTU to the PSC
PSC seri
serial
al port
port (loc
(located
ated insid
inside
e operator
operator c
cab),
ab), start
start tthe
he GE OHV w PTU
2. From
From th
the
e wi
wind
ndow
ow bro
brows
wser
er,, sel
selec
ectt PTU Screens –> PSC –> Normal_Operation –> Configuration –> Invert-
er Parameters (Fig. 49).
3. The Inverter Parameters screen is now displayed (Fig. 50).
NOTE: Parameter 25019 can only be changed through

through the Inverter
Inverter Parameters screen.
4. In the Inverter Parameter screen, in the Inv # all, Param # field, type in 25019 and press ENTER. The value
will return as 1.
5. Ch
Chan
ange
ge the
the p
par
aram
amet
eter
er by
by ttyp
ypin
ing
g 0 in the Inv # all, Value field and press ENTER.
6. Close th
the Inverter Parameter display screen by clicking on the X in the upper right corner of the screen.
7. Click on
on the Target button to go back to the GE OHV w PTU
PTU Toolbox Login screen and click on Terminal
Emulator Mode to start HyperTerminal.
8. Disc
Discon
onne
nect
ct the w PTU
PTU serial cable from the PSC serial port and connect it to the CNG (Inverter #1) serial port.
9. Press T to command the Inverter Test screen.
10. Press G to command the GTO test. The screen will display the following:
gto_switch_mode[HNWX1]:
11. Press N to access the GTO/CHOPPER Test, Command and Feedback screen.
NOTE: The switch modules

modules on the GE150AC
GE150AC system are IGBT’s.
IGBT’s. However
However,, the inverter software
software refers to
GTO’s. For the purposes of this testing, the terms are used interchangably.
* Tradenam
Tradename
e of Hilgra
Hilgraeve
eve Incorporat https://www.besttruckmanuals.com/
Incorporated
ed
70
FIG. 49. PTU BROWSER PSC

CONFIGURATION MENU ACCESS
SEQUENCE. E–44387B.
FIG. 50. INVERTER PARAMETERS SCREEN. E–45234.

71
NOTE: If any the following IGBT module checks fail, check IGBT module wiring. If wiring checks OK and
problem persists, replace phase module in question and/or inverter control card(s) until problem is cor-
rected.
12. Perform
Perform the follo
following
wing GTO/
GTO/IGBT
IGBT module
module command
command and feedbac
feedback
k checks:
a. Wi
With
th the w PTU
PTU connected to the CNG serial port, move the > sign to the letter F in the test column next to
GTO AUP.
b. Press T with the > sign at the letter F on the screen. Verify that the Fs in the command column and the Fs in
the feedback column should all turn to Ts.
c. Mov
ove
e the
the > sign to the letter
l etter the letter T in the test column next to GTO AUP.
d. Press F with the > sign at the letter T on the screen. Verify that the Ts in the command column and the Ts iin
n
the feedback column should all turn to Fs.
e. Repeat steps
steps a through
through d for each
each phase mod
module
ule or chopp
chopper
er in Inver
Inverter
ter #1.
13. Restore
Restore all settings
settings by p
perfor
erforming
ming the
the following
following steps
steps::
a. With
ith tthe
he w PTU
PTU still connected to the CNG serial port, make certain that all T values are returned to F
values.
b. With
ith the
the w PTU
PTU still connected to the CNG serial port, press X until the prompt invcpu> appears.
c. Di
Disc
scon
onne
nect
ct tthe
he w PTU
PTU serial cable from the CNG (Inverter #1) serial port and connect it to the PSC serial
port.
d. From
From the win
window
dow br
browse
owser,r, s
selec
electt PTU Screens –> PSC –> Normal_Operation –> Configuration –> In-
verter Parameters (Fig. 50).
e. Reset the
the para
parameter
meters
s for IInvert
nverter
er #1 from
from the Inverter Parameters screen.
14.
14. Cl
Clos
ose
e the
the Inverter Parameters display screen by clicking on the X in the upper right corner of the screen.
15.
15. With PTU connected to the PSC serial port, click on CMCTL to highlight and turn them ON, then press
With the w PTU
ENTER.
16. Discon
Disconnec
nectt the w PTU
PTU serial cable from the PSC serial port and connect it to the CNH (Inverter #2) serial port.
17. Repeat steps

steps 2 through 16 for Inverter
Inverter #2 tak
taking
ing note of the follo
following
wing diff
difference
erences:
s:
– All references to Inverter #1 are now for Inverter #2.
– All references to CNG are now for CNH.
– Shutdow
Shutdown
n the
the w PTU
PTU Toolbox
Toolbox and turn the PTU off before disconnecting it in step 16, then do not reconnect
it.
72
6.18
6.18.. SE
SELF
LF LO
LOAD
AD TE
TEST
STIN
ING
G
6.18
6.18.1
.1.. Pr
Prep
epar
arat
atio
ion
n fo
forr Se
Self
lf L
Loa
oad
dTTes
esti
ting
ng
Perform the following steps prior energizing equipment for the purpose of self load testing:
1. Place both Inverter

Inverter C
Cutout
utout switch
switches,
es, loc
located
ated on tthe
he righ
rightt hand side
side of the m
main
ain cont
control
rol cab
cabinet,
inet, iin
n the CUT
CUTOUT
OUT
(down) position.

Parking Brake (prop
(propulsion
ulsion syste
system
m commanded
commanded to REST
REST mode).
mode).
3. Verify that a
allll tape and/or
and/or other o
obstru
bstruction
ctions
s are removed
removed from tthe
he conta
contactor
ctor an
and
d contro
controll cabinet en
enclosur
closures
es for
proper air flow to the equipment.
WARNIN G: If a wheelmotor(s) has been removed, verify that its power cables are properly insulated in the
WARNING:
axle box.
NOTE: Self load testing can also be commanded through the DID panel (see Section 8.3.1., Self Load
Testing). If the DID panel is to be used, proceed to Section 6.18.2., Checks Prior to Self Load T
Testing.
esting.
4. Connect the PT
PTU
U to the PSC ser
serial
ial por
portt (loc
(located
ated in
in the op
operat
erator
or ca
cab),
b), st
start
art tthe
he GE OH
OHV
V w PTU
PTU Toolbox .
password, select PSC Panel, select appropriate truck type, and click on LOGIN to w PTU
5. From
From the wind
window
ow bro
brows
wser
er,, se
sele
lect
6.18
6.18.2
.2.. Ch
Chec
ecks
ks P
Pri
rior
or to Se
Self
lf Lo
Load
ad Tes
esti
ting
ng
6.18.2.1
6.18.2.1.. Batt
Battery
ery Boo
Boost
st Che
Check
ck
WARNING: This procedure MUST be be performed exactly as written. Failure to do so may result in
in person-
nel injury or death. The contactors in the contactor cabinet may be energized while the engine is runnin
running.
g.
The available potential even at engine idle is 700 volts at 180,000 amps.
1. Ver
erif
ify
y ttha
hatt eng
engine
ine is OFF
OFF..

Parking Brake (prop
(propulsion
ulsion syste
system
m commanded
commanded to REST
REST mode).
mode).
3. Place the GF Cutout

Cutout switch,
switch, located
located inside tthe
he cont
control
rol area o
off the mai
main
n contr
control
ol cabine
cabinet,
t, in the CU
CUTOUT
TOUT (d
(down)
own)
position.
4. Verif
Verify
y that all
all DC link
link volt
voltage
age indic
indicati
ating
ng lig
lights
hts a
are
re OFF
OFF..
5. Connect a voltm
voltmeter
eter acros
across
s resi
resistor
stor R
R1
1 which is loca
located
ted in tthe
he powe
powerr are
area
a of the m
main
ain co
contro
ntroll cabin
cabinet.
et. Connect
Connect
the positive lead to the R1 resistor terminal with wire number BAT, and the negative lead to the R1 resistor
terminal with wire number F101.
6. Cl
Clos
ose
e the
the comp
compar
artm
tmen
entt d
doo
oorr.
7. Star
Startt the en
engi
gine
ne..
8. Place
Place the
the GF Cutou
Cutoutt swi
switch
tch in th
the
e NORMAL
NORMAL (up)
(up) p
posi
ositio
tion.
n.
9. Apply the
the Load Brake,
Brake, release
release th
the
e Parkin
Parking
g Brake (p
(propul
ropulsion
sion system
system exi
exits
ts REST mode),
mode), an
and
d note that
that the
voltmeter will momentarily read approximately 18 V and then drop to zero volts.
73
NOTE: If the voltmeter reading is significantly different fro

from
m that stated above, remove voltage from the
propulsion
propulsion system. After verifying that
that voltage is removed from the propulsion
propulsion system, check resistor
R1 and its wiring, replace components and wiring as necessary, then repeat the above portion of the
procedure before continuing.
continuing.

Parking Brake
Brake (propulsion
(propulsion sys
system
tem com
commanded
manded to RE
REST
ST mode).
11. Place the GF Cutout switch,
switch, located on the rig
right
ht hand side of the main con
control
trol cabin
cabinet,
et, in the CUTOU
CUTOUT
T (down)
position.
12. Shut
Shut down
down the eng
engine
ine..
13. Verify
Verify that al
alll DC link voltage
voltage indicat
indicating
ing lights are
are OFF
OFF..
14. Disconnect
Disconnect and remove
remove the voltmeter
voltmeter and secur
secure
e the compart
compartment
ment door
door..
6.18
6.18.3
.3.. Se
Self
lf Lo
Load
ad Tes
estt P
Pro
roce
cedu
dure
re
After the procedures in Section 6.18.1.,Preparation for Self Load Testing and Section 6.18.2., Checks Prior
to Self Load Testing have been completed successfully
successfully,, conduct the Self Load T
Test
est as follows:
1. Verify
Verify tthat
hat the D
Directi
irection
on Se
Selector
lector switch is in the N
NEUTRAL
EUTRAL posit
position.
ion.
2. Verify
Verify th
that
at th
the
e Park
Parking
ing Brake
Brake is ON (propulsion
(propulsion syste
system
m comm
commanded
anded to REST mode)
mode)..
NOTE: Self load testing can also be commanded through the DID panel (see Section 8.3.1., Self Load
Testing).
Testi ng). If th
the
e DID panel is to be used without a wPTU , skip the remainder of this procedure and follow
the DID panel self load test procedure.
3. Close the PSC – Real Time Data display screen by clicking on the X in the upper right corner of the screen.
4. Fr
From
om the
the w
win
indo
doww br
brow
owse
serr, se
sele
lect
ct PTU Screens –> PSC –> Normal_Operation –> Tests –> Self Load En-
gine Test (Fig. 38).
5. The Self Load Engine Test screen is now displayed (Fig. 51).
6. Click on the ENTER LDBX button and verify on the Self Load Engine Test screen that the PSCMODE:
changes to TEST and the SUBSTATE: changes to LOADBOX before proceeding.
7. Press on the
the accelerat
accelerator
or pe
pedal.
dal. Engine speed must be abo
above
ve 1200
1200 RPM in order
order for RP1 to pickup which will
connect retarding grids across the alternator output.
NOTE: In the Loading section of the screen, if the HP ADJ value is consistently minus 200 (–200) or the
ENGLOAD value is 0.0%, that is an indication that the PWM engine load signal is not being communi-
cated to PSC.
8. Monitor the ENGLOAD value on the Self Load Engine Test screen during load testing.
testing. (This is a 0 tto
o 10 V
signal from the engine controller converted to a percentage value.)
a. If the value
value is 50% duri
during
ng load tes
testing,
ting, loa
loading
ding is opt
optimal.
imal.
b. If the value is below 50% during

during load testing,
testing, this
this is an indica
indication
tion of a weak en
engine
gine and the pr
propulsion
opulsion sys
system
tem
must decrease its load HP.
c. If the value
value is above 50% during load testing, this is an indication of a st
strong
rong engine and the propulsion
system can increase its load HP.
HP.
74
FIG. 51. SELF LOAD ENGINE TEST SCREEN. E–44394A.
9. When self lo
load
ad testing
testing iis
s complete,
complete, release
release the a
accele
ccelerato
ratorr peda
pedall and cli
click
ck on th
the
e EXIT LDBX button. Self load
testing should stop.
10
10.. Cl
Clos
ose
e the
the Self Load Engine Test display screen by clicking on the X in the upper right corner of the screen.
11. Cl
Clic
ick
k on
on the
PTU Tool-
75
6.19
6.19.. INVE
INVERT
RTER
ER LO
LOAD
AD TE
TEST
ST
WARNING: The inverter load test involves developing torque on the individual wheel motors at stand-
still. A location allowing
allowing for some movement
movement of the truck is required.
required. Personnel must
must stay clear of the
front and rear of the truck when an inverter is providing power to a wheel motor in order to avoid the risk
of injury, and possibly death, due to truck movement.
The truck cab
c ab must be manned at all times, or a means must be provided to stop the truck should motion
occur when an inverter is providing power to a wheel motor.
1. Shutdown the engine

engine and ensure
ensure the ffollowing
ollowing iin
n preparation
preparation ffor
or this ttest,
est, co
correct
rrecting
ing any pr
problems
oblems b
before
efore p
pro-
ro-
ceeding further:
a. The braking
braking sy
system
stem is ffunctio
unctional.
nal.
b. The wheel motors are clear

clear for rotat
rotation
ion and personnel
personnel are aware that wheels wil
willl be rotating one at a time.
c. If tires are not

not installed, verify
verify that the truck is solidly m
mounted
ounted on jack s
stands
tands and that the truck is stable.
2. Connect the PTU

PTU to th
the
e PSC serial
serial p
port
ort (locat
(located
ed in the
the oper
operator
ator cab)
cab),, sta
start
rt th
the
e GE OHV w PTU
3. From
From the wind
window
ow bro
brows
wser
er,, se
sele
lect
5. Place
Place the
the followi
following
ng swi
switch
tches
es in th
the
e pos
positio
itions
ns indica
indicated
ted::
a. Parking
Parking Brake sho
should
uld be ON (propulsion
(propulsion sys
system
tem comm
commanded
anded to REST m
mode).
ode).
b. Inverter
Inverter #2 Cuto
Cutout
ut switch
switch should be in the CUT
CUTOUT
OUT (down) po
position
sition..
c. Inverter
Inverter #1 Cu
Cutout
tout switch
switch sho
should
uld be in the N
NORMAL
ORMAL (u
(up)
p) posit
position.
ion.
6. Star
Startt the en
engi
gine
ne..
7. Release
Release the
the Pa
Parking
rking Brake (prop
(propulsion
ulsion syste
system
m ex
exits
its REST mode).
mode).
CAUTION: Do not accelerate the wheel motors
motors if the truck is on jack stands.
8. Place the Direction Selector

Selector switc
switch
h in the FORW
FORWARD
ARD position
position and v
verify
erify tthat
hat the truck
truck mo
moves
ves forward
forward if wh
wheels
eels
and tires are installed on the truck.
If the truck is on jack stands due to the absence of tires and/or wheels, view the left wheel motor. It should rotate
in a counter clockwise direction when viewed from the transmission end. The right wheel motor should not be
rotating.
If the truck movement or the wheel rotation is incorrect, stop the truck, stop the engine and correct the problem
before proceeding.
9. Re
Reco
cord
rd tthe
he foll
follow
owin
ing
g re
read
ading
ings
s on tthe
he PSC – Real Time Data screen:
a. Record the torque

torque command
command and fee
feedback
dback va
values
lues for IInvert
nverter
er #1 (TQCMD1 and TRQFB1 ). The minimum
torque command should be around 750 ft–lbs. Note any significant dif
differences.
ferences.
b. Record
Record both
both Inver
Inverter
ter #1 (I1LV) and Inverter #2 (I2LV) link voltages.
voltages. They should be approximately the
same with
wi th a maximum allowable differen
difference
ce of 7 V. The DC link volts should be approximat
approximately
ely 700 V and the
DC link amps should be less than 50 amps.
76
10. Place the

the Direct
Direction
ion Selec
Selector
tor swit
switch
ch in the NEU
NEUTRAL
TRAL pos
position.
ition.

Parking Brake
Brake (propulsion
(propulsion sys
system
tem com
commanded
manded to RE
REST
ST mode).
NOTE: All LEDs, the Inverter #1 cutout switch and the Inverter #2 cutout switch are not presen
presentt in the
17KG527B1 (or later) configuration of the 150 Ton AC control group.
12. Repeat steps
steps 5 through 10 for Inve
Inverter
rter #2 (with In
Inverter
verter #2 Cut
Cutout
out switch in NORMAL po
position
sition and Inve
Inverter
rter #1
Cutout switch in CUTOUT position in step 5), noting that if wheel rotation must be monitored, the right wheel
should be rotating clockwise when viewed from the transmission end and the left wheel should not be rotating.

Parking Brake (propulsion
(propulsion system com
commanded
manded to REST mode)
mode),, move both Invert
Inverter
er Cutout switc
switches
hes
to the NORMAL (up) position, then release the Parking Brake (propulsion system exits REST mode).
14. If wheels and tires

tires are inst
installed,
alled, ver
verify
ify that ttruck
ruck mov
moves
es forwa
forward
rd in a smooth m
manner
anner.. Stop the ttruck
ruck and m
move
ove
Direction Selector switch to REVERSE. Again verify that truck moves moves in reverse in a smooth manner.
manner.
If wheels and/or tires are not installed, verify that the wheel motors rotate in an even manner and that the follow-
ing wheel motor rotations as viewed from the transmission side are correct:
a. Direction
Direction Selector
Selector switch
switch in FORWAR
FORWARD
D –
(1) Left wheel m

motor
otor – coun
counter
ter c
clockwis
lockwise
e rotation
rotation
(2) Right wheel motor – clo

clockwise
ckwise rotation
rotation
b. Direction
Direction Selector
Selector switch in REVERSE
REVERSE –
(1) Left wheel motor

motor – clockw
clockwise
ise rrotatio
otation
n
(2) Right wheel motor – coun

counter
ter c
clockwis
lockwise
e rotation
rotation
NOTE: If problems are encountered

encountered during this
this testing, check the wheel motor
motor speed sensors, the speed
sensor wiring, wheel motor power cabling, and the inverter control card for problems.
15. When inverter testing is complete, move the Direction Selector switch to the NEUTRAL position, apply the
Parking Brake (propulsion system commanded to REST mode), move both Inverter Cutout switches to the
CUTOUT (down) position, and shut down the engine.
77
6.20.. FUNC
6.20 FUNCTIONA
TIONAL
L GROUN
GROUND
DFFAUL
AULT
T DET
DETECTIO
ECTION
N TES
TEST
T
This is a test procedure to ensure that the ground fault detection circuit is operational by placing a test wire jumper
from the propulsion system section of interest to truck frame ground. It is expected that ground faults will be detected
by the control system during this test.
WARNING: When installing or removing the test wire jumper fo forr ground fault detection checking, always
ensure that the truck is shut down, the engine is stopped, the Parking Brake is ON (propulsion
(propulsion system
commanded to REST mode), and A ALL
LL DC link voltage indicating
indicating lights are OFF.
OFF. Auxiliary DC link charged
indicating lights are provided on the top of the control for visual indication. It is recommended that the
auxiliary DC link be measured by separate instrumentation
instrumentation as well before proceeding with maintenance or
trouble shooting.
shooting. Failure to do so may result
result in personnel injury
injury or death.
If, for any reason, this test encounters ground fault detection problems (fails to detect entered fault), immediately
stop any further testing
testing and correct the problem. Each time a ground fault is detec
detected,
ted, a ground fault event is logged
logged in
the event summary log and propulsion power will be removed by the control system. Prior to removing the wire jumper,
ensure that the truck is shut down, the engine is stopped, the Parking Brake is applied (propulsion system commanded
to REST mode), and all DC link voltage indicating lights are OFF.
OFF. With the jumper removed, the ground faults can be
cleared and erased before proceeding further with the test.
The following circuits in the propulsion system should be checked by connecting one lead of the ground fault test
wire jumper to it and the other end to truck frame ground:
1. Posi
Posittive
ive DC
DC lin
link
kbbus
us
2. Nega
Negattive
ive DC
DC llin
ink
k bus
bus
78
7. STA
STATIST
TISTICA
ICAL
L DAT
DATA
A
7.1.
7.1. GE
GENE
NERA
RAL
LDDES
ESCR
CRIP
IPTI
TION
ON AN
AND
DDDEF
EFIN
INIT
ITIO
ION
N
The Statistical Data Collector uses Parameter Counters and Parameter Profiles to record operating condi-
tions for various occurrences on the truck.
To make data most useful, there are four counters for every Statistical Counter and five for every Statistical Profile.
These counts are named by the method used to reset the count to zero. For the counter, there is a lifetime count,
LCount , which is associated with its date, LCount Start. There are also three other counters, Last Qtr, This Qtr, and
This Day.
A parameter is a defined occurrence. Each parameter has an identificati

identification
on number called Par #, and a short name
called Description. Each parameter is an occurrence that is counted
counted in some unit such as hours or the number of
times the conditions have been correct to declare that the occurrence happened.
The units in which the counters count are listed under Units in TABLE 3, Statistical Data Codes – Counters
(located in this section). TABLE 3 also contains an additional explanation of the conditions that define a statistical
parameter as having occurred in the column titled Count Conditions.
There are two types of parameters: Counters (TABLE 3) and Profiles (TABL
TABLE E 4, Statistical Data Codes – Pro-
files, located in this section). The profile parameters have one more characteristic, Counter Range, identified by
Profile Number, which segments the possible range of values into a maximum of 17 ranges of values. The number or
count within a particular Counter Range or
or Profile Number is the time that the parameter had a value that was within
that range.
When examining the number of counts for a parameter, it is often useful to know over what period of time the counts
occurred. To aid in determining how long it took to get a certain number of counts for a Statistical Data Coun
Counter
ter param-
eter, the Statistical Data is presented in the form of four counters.
The first counter, LCount , indicates how many counts have occurred since the LCount Start date. This is in-
tended to be a lifetime counter. It can be reset to zero by a privileged user, and the LCount Start will automatically be
set to the date on the CPU

C PU board when the user performed the reset.
The second counter, Last Qtr is just the total number of counts for the parameter over the last–fiscal–quarter, also
known as the last–three–months.
last–three–months. This counter has the same value in it all quarter long. At midnight on a quarter
change, this counter is overwritten by the “This Qtr” value as this–quarter becomes last–quarter.
The third counter, This Qtr, keeps a moment by moment count of occurrences of the parameter. The counts are
not reset to zero until midnight of the next quarter.
The fourth counter, Last Mnth, keeps a moment by moment count of occurrences of the parameter over the last
month.
mon th. This counter has the same value in it all month long. At midnight on a month change, this counter is overwritten
overwr itten
by the This Mnth value as this–month becomes last–month.
The fifth counter, This Mnth, keeps a moment by moment count of occurrences of the parameter just as This Qtr,
except the This Mnth count is reset to zero at midnight of the next month.
The sixth counter,

counter, Yesterday, keeps a moment by moment count of occurrences of the parameter over the pre-
vious day. This counter has the same value in it all day long. At midnight, this counter is overwritten by the This Day
value as this–day becomes yesterday
yesterday..
79
FIG. 52. TCI ST

STAT_MENU
AT_MENU SELECTIONS.
E–44371A.
The seventh counter, This Day, keeps a moment by moment count of occurrences of the parameter just as This
Qtr, except the This Day count is reset to zero every midnight.
If the GE control panel is shut off before midnight, any necessary resetting of counters is done when the panel next
powers up after midnight.
Wheneve r the truck is programmed, that is, whenever the CPU Card has the contents of the flash proms changed,
Whenever
the LCount , Last Qtr, and This Qtr counts are not changed. However, the This Day count will be reset to zero.
7.2.
7.2. VIEW
VIEW S
ST
TATIST
TISTIC
ICAL
AL C
COU
OUNT
NTER
ERS
S
NOTE: It may be desirable
desirable to upload
upload Statistical
Statistical Counters
Counters to a PC for later view
viewing/analysis.
ing/analysis. Refer to
Section 3.8., Consolidated
Consolidated Truck Data Save Function, for procedures.
The w PTU
PTU provides the capability to view the current values of the statistical counters as follows:
TCI
CI serial
serial por
portt (located
operator
tor c
cab),
ab), s
start
PTU Toolbox,
Toolbox, enter
2. From
From tthe
he win
window
dow br
brow
owse
serr, sele
select
ct PTU Screens –> TCI –> Special_tasks –> Stat_Menu –> View Counters
(Fig. 52).
3. The View Counters screen is now displayed (Fig. 53).
4. Select the COUNTER Group to view from the menu on the screen, then click on View Counter Group.
5. The Mine Counters screen displaying the selected COUNTER Group is now displayed (Fig. 54).
6. Close th
the Mine Counters display screen by clicking on the X in the upper right corner of the screen.
7. Sele
Select
ct a d
dif
iffferen https://www.besttruckmanuals.com/
erentt COUNTER Group if desired by repeating step 4 or close the View Counters screen by click-
ing on the X in the upper right corner of the screen.
80
8. Click o
on he Target button to go back to the GE OHV w PTU
n tth PTU Toolbox Login screen, then close the w PTU
PTU
FIG. 53. VIEW COUNTERS SCREEN EXAMPLE. E–4521

E–45211.
1.
FIG. 54. MINE COUNTERS SCREEN (PSC_STA

(PSC_STATS).
TS). E–45212.
81
7.3.
7.3. VIEW
VIEW S
ST
TATIST
TISTIC
ICAL
AL P
PRO
ROFI
FILE
LES
S
NOTE: It may be desirable to upload Statistical Profiles to a PC for later viewing/analysis. Refer to Sec-
tion 3.8., Consolidated
Consolidated Truck Data Save Function, for procedures.
PTU provides the capability to view the current values of the statistical profiles as follows:
The w PTU follow s:

TCI
CI serial
serial por
portt (located
operator
tor c
cab),
ab), s
start
PTU Toolbox,
Toolbox, enter
2. From
From the
the w
win
indo
dow
w brow
browse
serr, se
sele
lect
ct PTU Screens –> TCI –> Special_tasks –> Stat_Menu –> View Profiles
(Fig. 52).
3. The View Mine Profiles screen is now displayed (Fig. 55).
4. Select the pro
profil
file
e tto
o vi
view
ew from
from the
the SELECT PROFILE TO VIEW menu on the screen, then click on VIEW PRO-
FILES .
5. The Mine Profiles screen displaying the selected profile is now displayed (Fig. 56).
6. Close th
the Mine Profiles display screen by clicking on the X in the upper right corner of the screen.
7. Select a dif
differe
ferent
nt pr
profile
ofile if desired
desired by re
repeat
peating
ing step
step 4 o
orr close
close th
the
e View Mine Profiles screen by clicking on the
8. Click
PTU
FIG. 55. VIEW PROFILES SCREEN EXAMPLE. E–45213.
82
FIG. 56. MINE PROFILES SCREEN (PSC_STATS).

(PSC_STATS). E–45214.
83
7.4.
7.4. VIEW
VIEW TR
TRUC
UCK
K ST
STA
AT SE
SERI
RIAL
AL RE
REPO
PORT
RT
NOTE: It may be desirable to upload Stat Serial Report to a PC for later viewing/analysis. Refer to Section
3.8., Consolidated Truck Data Save Function, for procedures.
PTU Toolbox
The w PTU Toolbox provides the capability to view the truck serial and configuration report as follows:
TCI
CI serial
serial por
portt (located
operator
tor c
cab),
ab), s
start
PTU Toolbox,
Toolbox, enter
2. Fro
From
m tthe
he win
window
dow bro
browse
wserr, s
sele
elect
ct PTU Screens –> TCI –> Special_tasks –> Stat_Menu –> Stat Serial Re-
port (Fig. 52).
3. The Stat Serial Report screen displaying the Serial & Configuration Report is now displayed (Fig. 57).
4. Close th
the Stat Serial Report display screen by clicking on the X in the upper right corner of the screen.
5. Click
PTU
7.5
7.5. RE
RESE
SET
T ST
STA
ATIST
STIC
ICS
S
Provided that the user has the appropriate privilege level, the w PTU
PTU Toolbox provides the capability to reset the
propulsion system statistics as follows:
TCI
CI serial
serial por
portt (located
operator
tor c
cab),
ab), s
start
PTU Toolbox,
Toolbox, enter
FIG. 57. https://www.besttruckmanuals.com/

STA
STATT SERIAL REPORT SCREEN. E–45219.
84
2. From
From the wind
window
ow bro
brows
wser
er,, se
select PTU Screens –> TCI –> Special_tasks –> Stat_Menu –> Reset Stats (Fig.
lect
52).
3. The Reset Stats screen displaying the Stat Reset Menu is now displayed (Fig. 58).
4. Reset
Reset the desire
desired
d st
stat
at (or sta
stats)
ts) on the
the Reset Stats screen using the following methods:
 Enter the counter to be reset in the RESET Individual COUNTER box and click on RESET Individual
COUNTER to perform the reset.
 Enter the profile to be reset in the Or, Enter Profile box and click on Or, Enter Profile to perform the reset.
 Select an individual profile to reset from the RESET Individual PROFILE menu and the Stat Profile Mine
Reset screen displays. Click on the desired timeframe for for the profile to select it (highlighted on screen),
then click in the YES, RESET THE SELECTED PROFILE box at the bottom of the screen to reset (Fig. 59).
Close either display screen by clicking on the X in the upper right corner of the screen.
 Click on any of the four reset

reset selection boxes and a question screen
screen displays. Click on Yes to reset the
selected statistics or No to leave the current statistics intact (Fig. 60).
5. Close tth
he Reset Stats display screen by clicking on the X in the upper right corner of the screen.
6. Click o
on
n tth
he Target button to go back to the GE OHV w PTU
PTU
FIG. 58. RESET ST
STATS
ATS SCREEN. E–45220.
85
FIG. 59. STA

STAT
T PROFILE MINE RESET SCREEN. E–45221.
FIG. 60. RESET BOX QUESTION SELECTION SCREENS. E–45223.
86
7.6..
7.6 UPL
UPLOAD
OAD ST
STA
ATISTI
TISTICAL
CAL DA
DAT
TA T
TO
O A FILE
FILE
In order to use the Statistical Data Collector to monitor maintenance of the vehicle, it is recommended that an office
spread sheet or data base computer program
program be used to keep periodic records of the statistical data. Also refer to
Section 3.8., Consolidated Truck Data Save Function .
To upload statistical data, do the following:

TCI seri
serial
al por
portt (loc
(located
ated in the opera
operator
tor c
cab),
ab), start
PTU Toolbox,
Toolbox, enter
refer to GEK–91712).
NOTE: Files are normally uploaded to the following:

c:/program files/geohvptu_xx/data_ac/<tru
files/geohvptu_xx/data_ac/<truck
ck id date time>
3. Sel
Select
ect the
the type
type of repo
report
rt to
to be s
save
aved
d from
from the
the Reports Type list, choose a Save Directory, then click on the
Begin button to begin uploading (Fig. 15).
4. Click on Close when the uploading is complete, then click on the Target button in the screen T
Tool
ool Bar to go to
the w PTU
PTU startup screen.
5. Close tth
he w PTU
PTU Toolbox,
87
TABLE 3. ST
STA
ATISTICAL DAT
DATA
A CODES – COUNTERS
Cntr. No. Description Units Count Conditions
301 Truck Life Hours The number of calendar hours that have elapsed since the
CPU
NOTE: has been
This loadedonly
counter with its
has current version
non–zero of software.
values in the
Lifetime Counter column.
302 Control Power On Hours The number of hours that the control power relay (CPR) has
been energized.
303 Engine Operate Hours The number of hours of engine operation above the engine
running threshold criteria.
304 Engine Idle Hours The number of hours when engine is idling and truck is sta-
tionary.
305 Truck Operate Hours The summation of the number of hours that the propulsion
system has operated in propulsion, retard, ready and test.
306 Truck Parked Hours The number of hours that the Park Brake applied feedback is
true while TCI is energized.
307 Truck Travel Miles The cumulative miles travelled

travelled by the truck. It is a calculated
value, based upon the integrated average of the four wheel-
motor speed signals. It is active when contrcontrol
ol power is on,
and it is not sensitive to vehicle direction.
308 Truck Travel Kilometers The cumulative kilometers travelled
travelled by the
the truck. It is a cal-
culated value, based upon the integrated average of the four
wheelmotor speed signals. It is active when cont control
rol power is
on, and it is not sensitive to vehicle direction.
309 Wheel 1 Operate Hours The number of hours that wheel #1 was providing torque in
either propulsion or retard, and was moving .
310 Wheel 2 Operate Hours The number of hours that wheel #2 was providing torque in
either propulsion or retard, and was moving .
311 Propel Forward Hours The number of hours that the truck was moving forward in
in
the propulsion mode of operation.
312 Retard Forward Hours The number of hours that the truck was moving forward in
in
the retard mode of operation.
313 Propel Mode Hours The number of hours that the truck was moving in the propul-
sion mode of operation.
314 Retard Mode Hours The number of hours that the truck was moving in the retard
mode of operation.
315 CPR Pickup Occurrences The number of times when the Keyswitch was moved from
the STOP to the ON position.
316 GF Pickup Occurrences The number of times that the GF contactor feedback has
changed from deenergized to energized indication.
317 GFR Pickup Occurrences The number of times that the GFR relay feedback has
318 RP1 Pickup Occurrences The numbfrom

changed er ofdeenergized
times that thto
eR P1 contacindication.
energized tor feedback has
319 RP2 Pickup Occhttps://www.besttruckmanuals.com/

urrences The number of times that the RP2 contactor feedback has
88
TABLE 3. ST
STA
ATISTICAL DA
DAT
TA CODES – COUNTERS (Cont’d)
320 RP3 Pickup Occurrences The number of times that the RP3 contactor feedback has

321 Dump Body Up Occurrences The number of times that the Dump Body position sensor
input has changed from true to false, indicating that the dump
body has been raised.
322 Loaded Truck Occurrences The n
nuumber of titimes tth
hat the Fu
Full P
Pa
ayload iin
nput ha
has changed
from false to true.
323 Speed Se
Set 1 Occurrences The n
nu
umber of
of titimes th
that th
the pr
programmable s
sp
peed s
se
et po
point
#1 has been exceeded.
324 Speed Se
Set 2 Occurrences The n
nu
umber of
of titimes th
that th
the pr
programmable s
sp
peed s
se
et po
point
#2 has been exceeded.
32
325
5 En
Engi
gine
ne St
Star
artt Sw
Swit
itch
ch Occu
Occurr
rren
ence
ces
s Th
Thee numb
number
er of time
times
s that
that the
the engi
engine
ne star
startt requ
reques
estt wa
was
s actu
actu--
ated by the operator’s Keyswitch.
32
326
6 Engi
Engine
ne On & S
Sta
tarrt Occu
Occurrrenc
rences
es The
The nu
num
mbe
berr of ti
tim
mes that
that engin
ngine
e star
startt requ
reques
estt rece
receiv
ived
ed wh
whil
ile
e
the engine above its running threshold criteria.
32
327
7 Sepa
Separa
ratte Bat
Battterie
eries
s Oc
Occu
currrenc
rences
es The
The num
numbe
berr of
of tim
times
es that
that the
the c
con
onttrol
rol and
and crank
rankin
ing
gbbat
attterie
eries
s
were commanded to separate.
328 Engine Crank Occurrences The number of times that a crank command has been issued
to the engine.
329 Engine Starts Occurrences The number of times that the measured engine speed has
exceeded the engine running criteria.
330 Engine Off Occurrences The number of times that the Engine Kill pushbutton was ac-
tuated.
33
331
1 Park
Park Brak
Brake
e Req
Reque
uest
st Occu
Occurrrenc
rences
es The
The num
numbe
berr of
of tim
times
es tha
hatt the
the Park
Park Brak
Brake
esswi
wittch wa
was
s act
actu-
u-
ated.
33
332
2 Park
Park Brak
Brake
e App
Appli
lied
ed Oc
Occu
currrenc
rences
es The
The num
numbe
berr of
of tim
times
es that
that the Par
Park B
Bra
rak
ke pprres
essu
sure
re swit
switch
ch
feedback transitioned from false to true, indicating that the
Park Brake was applied.
333 SS to Reverse Occurrences The number of times that the Direction Selector switch was
moved to the Reverse position.
334 SS to Forward Occurrences The number of times that the Direction Selector switch was
moved to the Forward position.
335 SS Wh
When M
Mo
oving
ing Occurrences The n
nu
umber of
of titimes th
that th
the Di
Direction
ion S
Se
elec
lector sw
switch w
wa
as
moved to command a change in direction while the truck was
moving.
336 RSC Sw
Switch On Occurrences The number of times that the Retard Speed Control switch was
moved from Off to On.
337 Rest Request Occurrences The number of times that the rest request was received by ac-
tuation of the Rest Request switch.
338 Override
ide Sw
Switc
itch Occurrences T
byheactuation
number o off tthe
imeOverride
s that theswitch.
override command was received
33
339
9 La
Lam
mp Tes
Testt Sw
Swit
itch
ch https://www.besttruckmanuals.com/
Oc
Occu
currrenc
rences
es The
The nu
number of
of titimes th
that th
the la
lamp te
test re
request w
wa
as rre
eceived by
by
actuation of the Lamp Test switch.
89
TABLE 3. ST
STA
ATISTICAL DA
DAT
340 Engine Ca
Cautions Occurrences The n
nu
umber of
of tim
time
es th
that th
the Engine C
Ca
autions signal from the
Engine Controller transitioned from low to high.

341 Engine OEM Over- Occurr
Occurrenc
ences
es The n
numb
umber
er of tim
times
es th
that
at tthe
he En
Engin
gine
e Spe
Speed
ed in
incre
crease
ases
s abo
above
ve
speed an OEM–settable limit.
342 Load Brake Occurrences (150 Ton) The number of times that the Load Brake input
transitioned from low to high.
343 Load Brake Seconds The amount of time that the Load Brake is applied.
344 Service Brake at Occurr
Occurrenc
ences
es The n
numb
umber
er of tim
times
es th
that
at tthe
he Se
Servi
rvice
ce Br
Brake
ake is
is app
applied
lied at
Speed speed.
345 Service Brake at Seco
Second
nds
s The
The am
amou
ount
nt of tim
ime
e tha
thatt the
the Serv
Servic
ice
eBBra
rake
ke is ap
appl
plie
ied
daatt
Speed speed.
346 Aux S
Sh
hutdowns Occurrences The nnu
umber of
of titimes th
that th
the a
au
ux_shutdown s
siignal tr
transi-
tioned from low to high.
347 Starter Fa
Failure Occurrences The n
nu
umber o
off titimes th
the e
en
ngine_starter_fail_di24 iin
nput tr
tran-
sitions to true.
348 Coasting Hours The number of hours that are spent coasting. Re
Ready mode
is active and Wheel #1 or Wheel #2 speed is above 50 rpm.
349 Rest Hours The number of hours that are spent in the Rest mode. R
Reest
mode is active.
350 Test Hours The number of hours that are spent in the Test mode. T
Te
est
mode is active.
351 Enter READY Occurrences The number of times that the READY mode has been en-
tered.
352 Enter Test Occurrences The number of times that the Test mode has been entered.
353 Enter Propel Occurrences The number of times that the Propel mode has been entered.
354 Enter Retard Occurrences The number of times that the Retard mode has been en-
tered.
355 Speed Control Ac- Occurr
Occurrenc
ences
es The n
numb
umberer of tim
times
es th
that
at p
prop
ropel
el torqu
torque
e is regu
regulat
lated
ed in the
tive speed limit mode.
356 M1 Spin Time Seconds The number of seconds that Wheel #1 Spin Control is active.
357 M1 Slide Time Seconds The number of seconds that Wheel #1 Slide Control is active.
358 M2 Spin Time Seconds The number of seconds that Wheel #2 Spin Control is active.
359 M2 Slide Time Seconds The number of seconds that Wheel #2 Slide Control is active.
360 M1 Spin Count Occurrences The number of times that Wheel #1
#1 Spin Control iis
s activated.
361 M1 Slide Co
Count Occurrences The nu
number of
of times th
that Wh
Wheel #
#1
1SSllide Co
Control iis
s
activated.
362 M2 Spin Count Occurrences The number of times that Wheel #2 Spin Control is
activated.
363 M2 Slide Co
Count Occurrences The nu
number of
activated. of times th
that Wh
Wheel #
#2
2SSllide Co
Control iis
s
364 Service Brake Time Sechttps://www.besttruckmanuals.com/

onds The number of seconds that the wet brake is applied and
truck speed is > no motion speed.
90
TABLE 3. ST
STA
ATISTICAL DA
DAT
36
365
5 Serv
Servic
ice
eBBra
rake
ke App
App Oc
Occu
currrenc
rences
es The
The num
numbe
berr of
of ti
time
mes
s tha
thatt the
the we
wett brak
brake
e iis
saapp
ppli
lied
ed an
and
d ttrruc
uck
k
speed is > no motion speed.

366 Load Box Mode Seconds The number of seconds that the system is in load box mode.
91
TABLE 3. ST
STA
ATISTICAL DA
DAT
Note::
Note Param
Parameter
eter Numbers
Numbers 1000 throug
through
h 1099 correspo
correspond
nd to DID Panel
Panel PSC Events
Events 000 th
throug
rough
h 099,

respectively (shown on DID panel and wPTU Toolbox).
1000 spare
1001 spare
1002 Ground Fault Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1003 Failed Diode Panel Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1004 GFCO Not Reset Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1005 Propulsion System Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
Over Temp
1006 Both Inv Comms Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
Failed
1007 spare
1008 DC Link Over Volt Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1009 ALTF Over Amps Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1010 spare
1011 Retard Lever Signal Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1012 Retard Pe
Pedal Si
Signal Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1013 Mid V Failure Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1014 Analog Sensor Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
Faults
1015 Restrictive An
Analog Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
Sensor Fault
1016 PSC CPU Card Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
Fault
1017 FB104 Digital Card Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1018 FB143 Analog Card Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1019 Riding Retard Pedal Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1020 High Torque Limit Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1021 TCI Comm Fault Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1022 Persistent TCI Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
Comm Fault
1023 Tertiary O
Ovvercurrent Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1024 CFG File Error Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1025 Blower Fault Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1026 Cap O
Ovverpressure Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1027 Panel Not Con- Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
nected at Power Up
1028 spare https://www.besttruckmanuals.com/
1029 spare
92
TABLE 3. ST
STA
ATISTICAL DA
DAT
1030 GF Contactor Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1031 Battery Boost Circuit Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1032 RP Contactors Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1033 RP–HP Balance Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1034 spare
1035 ESS Input Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1036 Grid Blower Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1037 Computer Power Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
Supply
1038 spare
1039 spare
1040 24V Positive Bad Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1041 24V Negative Bad Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1042 Self Load & Dir Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1043 Battery Volt Low Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1044 Battery Volt High Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1045 Chopper Open Cir- Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
cuit
1046 Retard Circuit Short Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1047 Engine Stall Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1048 Shorted DC Link Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1049 spare
1050 spare
1051 Tach Left Rear Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1052 Tach Right Rear Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1053 FLeft Speed Sig Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1054 FRight Speed Sig Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1055 Front Wheel Tachs Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1056 Inverter SW Version Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1057 spare
1058 spare
1059 spare
1060 spare
1061 Motor Over Speed Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1062 spare
1063 Engine Load Sig https://www.besttruckmanuals.com/
Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1064 spare
93
TABLE 3. ST
STA
ATISTICAL DA
DAT
1065 Temp Input Bad Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1066 spare
1067 spare
1068 spare
1069 spare
1070 Link Cap Level Get- Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
ting Low
1071 Link Cap Level Too Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
Low
1072 Gr
Gro
ound Fault Cir
irc
cuit Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
Problem
1073 Sensor Offset Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1074 INV1 Comm Failed Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1075 INV2 Comm Failed Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1076 FB173 Card Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1077 Inverter Failed VI Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
Test
1078 Inv Bkgnd Msg Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1079 spare
1080 spare
1081 spare
1082 spare
1083 spare
1084 CPS & Moving Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1085 Aux Cooling Fault Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1086 spare
1087 Engine HP Low Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1088 HP Over Limit Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1089 Engine Speed Com- Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
mand
1090 spare
1091 INV1 Cutout Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1092 INV2 Cutout Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1093 spare
1094 Limp Req Error Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1095 BBRAM Error Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1096 Unexpected S
Sy
ystem Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
Reset
94
TABLE 3. ST
STA
ATISTICAL DA
DAT
1097 spare
1098 PTU Data Store Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1099 Software E
Ev
vent Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
95
TABLE 3. ST
STA
ATISTICAL DA
DAT
Note::
Note Param
Parameter
eter Numbers
Numbers 1100
1100 throu
through
gh 1199
1199 corres
correspon
pond
d to Inverter
Inverter #1 Event Codes

100 through 199, respectively (shown on DID panel and wPTU Toolbox).
1100 INV1 CPU Card Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1101 INV1 CPU NR Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1102 INV1 I/O Card Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1103 INV1 I/O NR Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1104 INV1 FO Card Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1105 INV1 PS Card Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1106 INV1 DC Power Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1107 GDPS1 Fail Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1108 spare
1109 INV1 LinkV Fail Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1110 spare
1111 INV1 In
Input Vo
Volt Sen
Sen- Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
sor
1112 spare
1113 INV1 General Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1114 INV1 General NR Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1115 INV1 System Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1116 INV1 A Phase Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1117 INV1 A+ Phase Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1118 INV1 A+ Phase NR Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1119 INV1 A– Phase Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1120 INV1 A– Phase NR Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1121 INV1 A Phase Am
Amps Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1122 spare
1123 INV1 A Phase Volts Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1124 spare
1125 INV1 B Phase Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1126 INV1 B+ Phase Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1127 INV1 B+ Phase NR Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1128 INV1 B– Phase Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1129 INV1 B– Phase NR Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1130 INV1 B Phase Am
Amps Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1131 spare
1132 INV1 B Phase Volts Occhttps://www.besttruckmanuals.com/
urrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1133 spare
96
TABLE 3. ST
STA
ATISTICAL DA
DAT
1134 INV1 C Phase Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1135 INV1 C+ Phase Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1136 INV1 C+ Phase NR Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1137 INV1 C– Phase Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1138 INV1 C– Phase NR Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1139 spare
1140 spare
1141 INV1 C Phase Volts Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1142 spare
1143 INV1 Tach 1 Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1144 INV1 Tach 1 NR Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1147 spare
1148 Chopper 1 NR Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1149 spare
1151 INV1 Misc Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1152 spare
1153 INV1 Motor Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1154 INV1 Motor Faults Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
NR
1155 INV1 Second Load Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1156 thru spare
1199
97
TABLE 3. ST
STA
ATISTICAL DA
DAT
Note::
Note Param
Parameter
eter Numbers
Numbers 1200 throug
through
h 1299 correspo
correspond
nd to Inverter
Inverter #2 Event
Event Code
Codes
s

200 through 299, respectively (shown on DID panel and wPTU Toolbox).
1200 INV2 CPU Card Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1201 INV2 CPU NR Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1202 INV2 I/O Card Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1203 INV2 I/O NR Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1204 INV2 FO Card Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1205 INV2 PS Card Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1206 INV2 DC Power Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1207 GDPS2 Fail Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1208 spare
1209 INV2 LinkV Fail Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1210 spare
1211 INV2 Input Volt Sen
Sen- Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
sor
1212 spare
1213 INV2 General Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1214 INV2 General NR Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1215 INV2 System Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1216 INV2 A Phase Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1217 INV2 A+ Phase Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1218 INV2 A+ Phase NR Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1219 INV2 A– Phase Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1220 INV2 A– Phase NR Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1221 INV2 A Phase Amps Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1222 spare
1223 INV2 A Phase Volts Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1224 spare
1225 INV2 B Phase Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1226 INV2 B+ Phase Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1227 INV2 B+ Phase NR Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1228 INV2 B– Phase Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1229 INV2 B– Phase NR Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1230 INV2 B Phase Amps Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1231 spare
1232 INV2 B Phase Volts Occhttps://www.besttruckmanuals.com/
1233 spare
98
TABLE 3. ST
STA
ATISTICAL DA
DAT
1234 INV2 C Phase Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1235 INV2 C+ Phase Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1236 INV2 C+ Phase NR Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1237 INV2 C– Phase Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1238 INV2 C– Phase NR Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1239 spare
1240 spare
1241 INV2 C Phase Volts Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1242 spare
1247 spare
1249 spare
1251 INV2 Misc Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1252 spare
1253 INV2 Motor Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1254 INV2 Motor Faults Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
NR
1255 INV2 Se
Second Lo
Load Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1256 thru spare
1299
99
TABLE 3. ST
STA
ATISTICAL DA
DAT
Note::
Note Param
Parameter
eter Number
Numbers
s 1600 through
through 1699
1699 correspon
correspond
d to TCI E
Event
vents
s 600 through
through 699,
699,

respectively (shown on DID panel and wPTU Toolbox).
1600 spare
1601 FB144 CPU Card Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1602 FB104 Digital I/O Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1603 FB160 Analog I/O Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1604 PSC Comm Bad Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1605 Aux Comm Fault Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1606 spare
1609 15V Negative Bad Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1610 Pot Ref Bad Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1611 spare
1612 spare
1613 Analog Input Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1614 BSep Cont Fail Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1615 spare
1616 Forin & Revin Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1617 Eng Start Denied Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1618 spare
1619 Engine Warning Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1620 Eng Kill & Speed Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1621 spare
1622 Park B
Brrake P
Prroblem Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1623 Hyd Br
Brake Fl
Fluid Ho
Hot Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1624 Body Up & Load Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1625 Body Up & Speed Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1626 Load Brake & Speed Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1627 spare
1628 Battery Volts Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1629 Baro Press Signal Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1630 Motor Blower Press Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1631 Amb Temp Signal Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1632 CFG File Error Occhttps://www.besttruckmanuals.com/
1633 BBRAM Error Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
100
TABLE 3. ST
STA
ATISTICAL DA
DAT
1634 Overload Re
Restrictive Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1635 Overload NR Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1636 Aux Inverter Faults Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1637 spare
1638 Engine Cr
Crank T
Tiime- Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
out
1639 Engine Start Re- Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
quest & Running
1640 Accel Pe
Pedal to
too Hi
High Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1641 Accel Pedal too Low Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1642 Crank Override Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1643 thru spare
1690
1691 spare
1692 spare
1693 spare
1694 spare
1695 spare
1696 Unexpected CPU Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
Reset
1697 spare
1698 Data Store Occurrences See TABLE 5 – EVENT CODE DESCRIPTIONS
1699 spare
101
7.7.
7.7. PR
PROF
OFIL
ILE
E (HIS
(HIST
TOG
OGRA
RAM)
M) DE
DEFI
FINI
NITI
TION
ONS
S
The word histogram is used in the definitions of the

the various statistical profiles in the
the following table. A histogram
is a collection of statistical data organized into defined ranges of values. The graphical representation of a histogram
is typically a bar chart.
TABLE 4. ST
STA
ATISTICAL DAT
DATA
A CODES – PROFILES
Prof. No. Description Count Conditions
401 Alt HPNET IIn
n This is a histogram of alte
lternator input horsepower. The sample time is 1.0
second. The clock ststarts
arts whenever the truck is in the propel state. The his-
togram breaks the horsepower spectrum into 17 buckets, and displays the
time that was spent in each bucket. The buckets are defined as ffollows:
ollows:
NUMBER NET IIN
NPUT HO
HORSEPOWER R
RA
ANGE
1. 450 and below
2. 451 to 650
3. 651 to 850
4. 851 to 1050
5. 1051 to 1250
6. 1251 to 1450
7. 1451 to 1650
8. 1651 to 1850
9. 1851 to 2050
10. 2051 to 2150
11. 2151 to 2250
12. 2251 to 2350
13. 2351 to 2450
14. 2451 to 2550
15. 2551 to 2650
16. 2651 to 2750
17. 2751 and above
40
402
2 Cont
Contrrol Batt
Batter
ery
y This
This clock
The is a hist
hiwill
stog
ograram
runm of Co
Cont
ntrrol
whenever Batt
Bacontrol
the tter
ery
y Volt
oltage.
age. The
system Th e sam
sample
is up. ple tim
time
e is 1 seco
second
nd..
NUMBER VOLTAGE RANGE

1. 12 and below
2. >12 to ≤14
3. >14 to ≤16
4. >16 to ≤18
5. >18 to ≤20
6. >20 to ≤22
7. >22 to ≤24
8. >24 to ≤26
9. >26 to ≤27
10. >27 to ≤28
11. >28 to ≤29
12. >29 to ≤30
13. >30 to ≤32
14. >32 to ≤34
15. https://www.besttruckmanuals.com/
>34 to ≤36
16. >36 to ≤38
17. 38 and above
102
TABLE 4. ST
STA
ATISTICAL DA
DAT
TA CODES – PROFILES (Cont’d)
403 Crank Battery ( 27
2700 This is a histogram of Crank Battery Voltage.
Voltage. The sample time is 1 second.
HP and 3500 HP
Only) Theonly.)
AC clock will run whenever the control system is up. (Truck_type
(Truck_type = 320 T
Ton
on
NUMBER VOLTAGE RANGE
1. ≤ 2
2. >2 to ≤4
3. >4 to ≤6
4. >6 to ≤8
5. >8 to ≤10
6. >10 to ≤12
7. >12 to ≤14
8. >14 to ≤16
9. >16 to ≤18
10. >18 to ≤20
11. >20 to ≤22
12. >22 to ≤24
13. >24 to ≤26
14. >26 to ≤28
15. >28 to ≤30
16. >30 to ≤32
17. >32
404 Spare
40
405
5 Reta
Retarrd M
Mod
ode
e HP
HP This
This is a his
histtog
ogra
ram
mo off D
DC
C lin
link
kHHP
Pwwhi
hile
le in the
the rret
etar
ard
dmmodode.
e. The
The ssam
ampl
ple
e ttim
ime
e
is 1.0 second. The clock starts whenever the ttruck ruck is in the retard mode.
mode.
The histogram breaks the horsepower spectrum into 17 buckets, and displays
the time that was spent
spent in each bucket. The buckets are defined as ffollows:
ollows:
NUMBER HORSEPOWER R RA
ANGE
1. 800 and below
2. 801 to 1200
3. 1201 to 1600
4. 1601 to 2000
5..
6 24
200
01
1 tto
o228
40
00
0
7. 2801 to 3200
8. 3201 to 3600
9. 3601 to 3800
10. 3801 to 4000
11. 4001 to 4200
12. 4201 to 4400
13. 4401 to 4600
14. 4601 to 4800
15. 4801 to 5000
16. 5001 to 5200
17. 5201 and above
406 Spare
103
TABLE 4. ST
STA
ATISTICAL DA
DAT
40
407
7 Truc
uck
k Spd
Spd MP
MPH
H This
This is a hist
histog
ogrram of truc
truck
k spee
speed
d in mph for
for all
all modes
odes of op
oper
erat
atio
ion.
n. The
The
clock starts
second. Thewhenever control
histogram power
breaks (CPR)
the MPH is on. Sample
spectrum into 17time is every
s, and1.0
buckets,
bucket dis-
plays the time that was spent in each bucket. The buckets are defined as
follows:
NUMBER TRUCK S SPPEED R
RA
ANGE ((M
MPH)
1. 2.0 and below
2. 2.1 to 4.0
3. 4.1 to 5.0
4. 5.1 to 6.0
5. 6.1 to 8.0
6. 8.1 to 10.0
7. 10.1 to 12.0
8. 12.1 to 17.0
9. 17.1 to 22.0
10. 22.1 to 27.0
11. 27.1 to 32.0
12. 32.1 to 37.0
13. 37.1 to 39.0
14. 39.1 to 41.0
15. 41.1 to 43.0
16. 43.1 to 45.0
17. 45.1 and above
40
408
8 Truc
uck
k Spd
Spd KP
KPH
H This
This is a hist
histog
ogrram of truc
truck
k spee
speed
d in kph
kph for all
all modes
odes of op
oper
erat
atio
ion.
n. The
The
clock starts whenever control
control power (CPR) is on. Sample time is every 1.0
second. The histogram breaks the KPH spectrum into 17 buckets, and dis-
follows:
NUMBER TRUCK S SPPEED R
RA
ANGE ((K
KPH)
1. 3.0 and below
2. 3.1 to 6.4
3. 6.5 to 8.0
4. 8.1 to 9.6
5. 9.7 to 12.8
6. 12.9 to 16.0
7. 16.1 to 19.0
8. 19.1 to 27.0
9. 27.1 to 35.0
10. 35.1 to 43.0
11. 43.1 to 51.0
12. 51.1 to 60.0
13. 60.1 to 63.0
14. 63.1 to 66.0
15. 66.1 to 69.0
16. 69.1 to 72.0
17. 72.1 and above
104
TABLE 4. ST
STA
ATISTICAL DA
DAT
409 Motor 1 RPM This is a hist
istogram of Motor #1 rpm for all modes of operation
ion. The clock
starts whenever
cond. control
The histogram powerthe
breaks (CPR)
RPMisspectrum
on. Sample
into time is every
17 buckets,
buckets 1.0 dis-
, and se-
follows:
NUMBER MOTOR 1 SPEED RANGE (RPM)
1. 70 and below
2. 71 to 287
3. 288 to 452
4. 453 to 567
5. 568 to 735
6. 736 to 900
7. 901 to 1050
8. 1051 to 1200
9. 1201 to 1500
10. 1501 to 1800
11. 1801 to 2100
12. 2101 to 2400
13. 2401 to 2700
14. 2701 to 3000
15. 3001 to 3150
16. 3151 to 3300
17. 3301 and above
410 Motor 2 RPM This is a hist
istogram of Motor #2 rpm for all modes of operation
ion. The clock
starts whenever control power (CPR) is on. Sample time is every 1.0 se-
cond. The histogram breaks the RPM spectrum into 17 buckets,
buckets, and dis-
follows:
NUMBER MOTOR 2 SPEED RANGE (RPM)
1. 70 and below
2. 71 to 287
3. 288 to 452
4. 453 to 567
5. 568 to 735
6. 736 to 900
7. 901 to 1050
8. 1051 to 1200
9. 1201 to 1500
10. 1501 to 1800
11. 1801 to 2100
12. 2101 to 2400
13. 2401 to 2700
14. 2701 to 3000
15. 3001 to 3150
16. 3151 to 3300
17. 3301 and above
105
TABLE 4. ST
STA
ATISTICAL DA
DAT
41
411
1 Ev
Even
entt 6
636
36 Su
Sub–
b–id
id Th
This
is is a h
his
isto
togr
gram
am of the
the n
num
umbe
berr of
of tim
times
es each
each Ev
Even
entt 6
636
36,, A
Aux
ux Blow
Blower
er Fa
Fail
il--
ure, sub–ID
propriate logs.isEach
bucket time theby
incremented aux
1. cont
controller
roller sends
(Truck_type a 636
= 320 Tonsub–ID
Ton the
AC only .) ap-
only.)
The buckets are defined as follows:
NUMBER
1. sub–ID 1
2. sub–ID 2
3. sub–ID 3
4. sub–ID 4
5. sub–ID 5
6. sub–ID 6
7. sub–ID 7
8. sub–ID 8
9. sub–ID 9
10. sub–ID 10
11. sub–ID 11
12. sub–ID 12
13. sub–ID 13
14. sub–ID 14
15. sub–ID 15
41
412
2 Serv
Servic
ice
e Bra
Brake
kes
s This
This is a hist
histog
ogrram of the
the Serv
Servic
ice
e Brak
Brake
e ap
appl
plie
ied
d inp
input
ut ( Wet or Dry
Dry brak
brakes
es))
being active. The clock starts whenever control power (CPR) is on. Sample
time is every 1.0 seconds.
NUMBER
1. 2.0 or less
2. 2.1 to 4.0
3. 4.1 to 5.0
4. 5.1 to 6.0
5. 6.1 to 8.0
6. 8.1 to 10.0
7..
8 12
10..1
1 tto
o117
2..0
0
9. 17.1 to 22.0
10. 22.1 to 27.0
11. 27.1 to 32.0
12. 32.1 to 37.0
13. 37.1 to 39.0
14. 39.1 to 41.0
15. 41.1 to 43.0
16. 43.1 to 45.0
17. 45.1 or greater
106
TABLE 4. ST
STA
ATISTICAL DA
DAT
413
413 Ambi
Ambien
entt Tem
Temp
p Low
Low This
This is a h
his
isto
togr
gram
am of am
ambi
bien
entt temp
temper
erat
atur
ure.
e. The
The cloc
clock
k star
starts
ts wh
when
enev
ever
er con-
con-
trol power
breaks the(CPR) is on. spectrum
temperature Sample time
intois17every 1.0 seconds.
buckets, Thethe
and displays histogram
time that
was spent in each bucket. The buckets are defined as follows:
NUMBER TEMPERATURE RANGE (DEGREE C)
1. –40 and below
2. –39 to –30
3. –29 to –25
4. –24 to –20
5. –19 to –15
6. –14 to –10
7. –9 to –5
8. –4 to 0
9. 1 to 5
10. 6 to 10
11. 11 to 15
12. 16 to 20
13. 21 to 25
14. 26 to 30
15. 31 to 35
16. 36 to 40
17. 41 and above
414
414 Ambi
Ambien
entt T
Tem
emp
pHHig
igh
h This
This is a h
his
isto
togr
gram
am of am
ambi
bien
entt tem
tempe
pera
ratu
ture
re.. The
The c
clo
lock
ck star
starts
ts wh
when
enev
ever
er con-
con-
trol power (CPR) is on. Sample time is every 1.0 seconds. The histogram
breaks the temperature spectrum into 17 buckets, and displays the time that
was spent in each bucket. The buckets are defined as follows:
NUMBER TEMPERATURE RANGE (DEGREE C)
1. 35 and below
2. 36 to 37
3. 38 to 39
4. 40 to 41
5. 42 to 43
6. 44 to 45
7. 46 to 47
8. 48 to 49
9. 50 to 51
10. 52 to 53
11. 54 to 55
12. 56 to 57
13. 58 to 59
14. 60 to 61
15. 62 to 63
16. 64 to 65
17. 66 and above
107
TABLE 4. ST
STA
ATISTICAL DA
DAT
415 Engine Speed This is a histogram of engine speed in rpm for all modes of operation. The
clock starts whenever
1.0 seconds. control breaks
control
The histogram power (CPR) pmisspectrum
the rrpm on. The sample time iss,every
into 17 buckets,
bucket and
displays the time spent in each
each bucket. The buckets are defined as follows:
NUMBER ENGINE SPEED RANGE (RPM)
1. 750 and below
2. 751 to 850
3. 851 to 950
4. 951 to 1050
5. 1051 to 1150
6. 1151 to 1250
7. 1251 to 1350
8. 1351 to 1450
9. 1451 to 1550
10. 1551 to 1650
11. 1651 to 1750
12. 1751 to 1850
13. 1851 to 1950
14. 1951 to 2050
15. 2051 to 2150
16. 2151 to 2250
17. 2251 and above
416 Engine Cr
Cranking This is a histogram of the time duration of active engine cranking commands
Command Active for each attempted crank.
crank. The histogram breaks the time duration spectrum
into 17 buckets, and displays the number of engine crank commands whose
time duration was in each bucket. The buckets are defined as follows:
NUMBER ENGINE CR CRANKI
NKING C
CO
OMMAND A
AC
CTIV
TIVE ((S
SEC)
1. 1 and below
2. 2 to 4
3. 5 to 6
4. 7 to 8
5. 9 to 10
6. 11 to 15
7. 16 to 20
8. 21 to 25
9. 26 to 30
10. 31 to 40
11. 41 to 50
12. 51 to 60
13. 61 to 70
14. 71 to 80
15. 81 to 90
16. 91 to 100
17. 101 and above
108
TABLE 4. ST
STA
ATISTICAL DA
DAT
417 Engine Cranking In- This is a histogram of the time interval in minutes between engine cranking
tervals
(in minutes) attempts.
and The
displays histogram
the number ofbreaks
times the time
each int
interval
ervaltime
bucket’s spectrum
intervalinto 17 buckets,
between engine
cranking attempts was recorded.
recorded. The buckets are defined as follows:
NUMBER ENGINE CRA RAN
NKING INTERVAL (MIN)
1. 0.5 and below
2. 1.0 to 2.0
3. 2.1 to 3.0
4. 3.1 to 4.0
5. 4.1 to 5.0
6. 5.1 to 6.0
7. 6.1 to 7.0
8. 7.1 to 8.0
9. 8.1 to 9.0
10. 9.1 to 10.0
11. 10.1 to 11.0
12. 11.1 to 12.0
13. 12.1 to 13.0
14. 13.1 to 14.0
15. 14.1 to 15.0
16. 15.1 to 20.0
17. 20.1 and above
41
418
8 Acce
Accell Peda
Pedall % This
This is a hist
histog
ogra
ram
m of the Acce
Accell Peda
Pedall pe
perrce
cent
ntag
age
e dur
during
ing Prop
Propel
el.. The
The sam
sample
ple
time is every 1.0 seconds. The buckets are defined as follows:
NUMBER
1. 6 or less
2. 6.1 to 12
3. 12.1 to 18
4. 18.1 to 24
5. 24.1 to 30
6. 30.1 to 36
7. 36.1 to 42
8. 42.1 to 48
9. 48.1 to 54
10. 54.1 to 60
11. 60.1 to 66
12. 66.1 to 72
13. 72.1 to 78
14. 78.1 to 84
15. 84.1 to 90
16. 90.1 to 96
17. 96.1 or greater
109
TABLE 4. ST
STA
ATISTICAL DA
DAT
41
419
9 RSC
RSC Per
Perc
cen
enta
tage
ge This
This is a h
his
isttog
ogra
ram
mooff the
the Ret
Retard
ard S
Spe
peed
ed Cont
Contrrol Perc
Percen
enta
tage
ge The
The s
sam
ampl
ple
e
NUMBER
1. 6 or less
2. 6.1 to 12
3. 12.1 to 18
4. 18.1 to 24
5. 24.1 to 30
6. 30.1 to 36
7. 36.1 to 42
8. 42.1 to 48
9. 48.1 to 54
10. 54.1 to 60
11. 60.1 to 66
12. 66.1 to 72
13. 72.1 to 78
14. 78.1 to 84
15. 84.1 to 90
16. 90.1 to 96
17. 96.1 or greater
42
420
0 Pot
Pot Ref
Refer
eren
enc
ce This
This is a his
histogr
togram
am of the po
pott ref
referen
erence
ce va
valu
lue.
e. The
The sa
samp
mple
le ti
tim
me is ev
ever
ery
y 1.0
1.0
seconds. The buckets are defined as follows:
NUMBER
1. 5 or less
2. >5 to ≤8
3. >8 to ≤8.5
4. >8.5 to ≤9
5. >9 to ≤9.5
6. >9.5 to ≤10
7. >10 to ≤10.5
8. >10.5 to ≤11
9. >11 to ≤11.5
10. >11.5 to ≤12
11. >12 to ≤12.5
12. >12.5 to ≤13
13. >13 to ≤13.5
14. >13.5 to ≤14
15. >14 to ≤14.5
16. >14.5 to ≤15
17. >15.1 or greater
110
TABLE 4. ST
STA
ATISTICAL DA
DAT
42
421
1 Spee
Speed
d Unl
Unloa
oad
ded This
This is a h
his
isttog
ogra
ram
mooff the
the truc
ruck s
spe
peed
ed whil
while
e the
the truck
ruck is unlo
unload
aded
ed The
The s
sam
am--
ple time is every 1.0 seconds. The buckets are defined as follows:
NUMBER
1. 2.5 or less
2. >2.5 to 5
3. >5 to ≤7.5
4. >7.5 to ≤10
5. >10 to ≤12.5
6. >12.5 to ≤15
7. >15 to ≤17.5
8. >17.5 to ≤20
9. >20 to ≤22.5
10. >22.5 to ≤25
11. >25 to ≤27.5
12. >27.5 to ≤30
13. >30 to ≤32.5
14. >32.5 to ≤35
15. >35 to ≤37.5
16. >37.5 to ≤40
17. 40 or greater
422 Speed Loaded This is
is a histogram of th
the ttrruck sp
speed w
wh
hile tth
he ttrruck iis
s lo
loaded The s
sa
ample
NUMBER
1. 2.5 or less
2. >2.5 to 5
3. >5 to ≤7.5
4. >7.5 to ≤10
5. >10 to ≤12.5
6. >12.5 to ≤15
7. >15 to ≤17.5
8. >17.5 to ≤20
9. >20 to ≤22.5
10. >22.5 to ≤25
11. >25 to ≤27.5
12. >27.5 to ≤30
13. >30 to ≤32.5
14. >32.5 to ≤35
15. >35 to ≤37.5
16. >37.5 to ≤40
17. 40 or greater
111
111
TABLE 4. ST
STA
ATISTICAL DA
DAT
422 Speed Loaded This is
is a histogram of th
the tr
truck s
sp
peed w
wh
hile th
the ttrruck is
is llo
oaded The s
sa
ample
NUMBER
1. 2.5 or less
2. >2.5 to 5
3. >5 to ≤7.5
4. >7.5 to ≤10
5. >10 to ≤12.5
6. >12.5 to ≤15
7. >15 to ≤17.5
8. >17.5 to ≤20
9. >20 to ≤22.5
10. >22.5 to ≤25
11. >25 to ≤27.5
12. >27.5 to ≤30
13. >30 to ≤32.5
14. >32.5 to ≤35
15. >35 to ≤37.5
16. >37.5 to ≤40
17. 40 or greater
42
423
3 Hy
Hyd
d Brak
Brake
e De
Deg
g This
This is a hist
histog
ogrram of Aux
Aux Blow
Blower
er Inv
Invert
erter tem
tempe
pera
ratture.
ure. The
The sam
sample
ple tim
ime
e is
every 1.0 seconds. The clock will start whenever control
control power (CPR) is on.
All temperatures are in degrees
degrees C. The histogram breaks the temperature
spectrum into 17 buckets and displays the time that was
w as spent in each buck-
et. The buckets are defined as follows: (Truck_type
(Truck_type = 320 TTon
on AC only.)
only.)
NUMBER TEMPERATURE RANGE
1. <20
2. >20 to ≤40
3. >40 to ≤50
4. >50 to ≤60
5. >60 to ≤70
≤
6
7.. >
>7
80
0 tto
o ≤80
90
8. >90 to ≤95
9. >95 to ≤100
10. >100 to ≤105
11. >105 to ≤110
12. >110 to ≤115
13. >115 to ≤120
14. >120 to ≤125
15. >125 to ≤130
16. >130 to ≤140
17. >140
112
TABLE 4. ST
STA
ATISTICAL DA
DAT
424 Baro P
Prressure This is
is a histogram o
off th
the B
Ba
arometric Pressure, ai
ai_03 iin
n TCI
TCI.. The s
sa
ample
time
is on.is All
every 1.0 seconds.
pressure The per
is in pounds clock will start
square inchwhenever control
cont
(PSI). The rol powerbreaks
histogram (CPR)
the pressure spectrum into 17 buckets, and displays the time that was spent
in each bucket. The buckets are defined as follows:
NUMBER PRESSURE RANGE (PSI)
1. < 7.5
2. >7.5 to 8.0
3. >8.0 to ≤8.5
4. >8.5 to ≤9.0
5. >9.0 to ≤9.5
6. >9.5 to ≤10.0
7. >10.0 to ≤10.5
8. >10.5 to ≤11.0
9. >11.0 to ≤11.5
10. >11.5 to ≤12.0
≤
112. >12.0
5 to ≤12.5
13.0
13. >13.0 to ≤13.5
14. >13.5 to ≤14.0
15. >14.0 to ≤14.5
16. >14.5 to ≤15.0
17. >15.0
425 Loadbox HP This is a histogram of Loadbox Horsepower. The sample time is every 1.0
seconds. If the system is in loadbox mode, the T Total
otal Engine Horsepower
(HP) is recorded.
recorded. All values are in HP
HP.. The histogram breaks the HP spec-
trum into 17 buckets, and displays the time that was spent in each bucket.
NUMBER HP
1. ≤100
2. >100 to 650
3 ≤
4.. >
>6
85
50
0 tto
o ≤850
1050
5. >1050 to ≤1250
6. >1250 to ≤1450
7. >1450 to ≤1650
8. >1650 to ≤1850
9. >1850 to ≤2050
10. >2050 to ≤2250
11. >2250 to ≤2450
12. >2450 to ≤2650
13. >2650 to ≤2850
14. >2850 to ≤3250
15. >3250 to ≤3450
16. >3450 to ≤3650
17. >3650
113
113
TABLE 4. ST
STA
ATISTICAL DA
DAT
42
426
6 Mot
Motor 1 Hi RPM
RPM This
This is a h
his
isttog
ogra
ram
m of the Mot
Motor 1 R
RPM
PM.. The
The sam
sample
ple ti
tim
me is
is ev
ever
ery
y 1.0
1.0 sec-
sec-
onds. All values
17 buckets, are in RPM.
and displays Thethat
the time histogram breaks
was spent theh RPM
in eac
each spectrum
bucket. into
The buck-
ets are defined as follows:
NUMBER RPM
1. ≤3300
2. >3300 to 3400
3. >3400 to ≤3500
4. >3500 to ≤3600
5. >3600 to ≤3700
6. >3700 to ≤3800
7. >3800 to ≤3900
8. >3900 to ≤4000
9. >4000 to ≤4100
10. >4100 to ≤4200
11. >4200 to ≤4300
12. >4300 to ≤4400
13. >4400 to ≤4500
14. >4500 to ≤4600
15. >4600 to ≤4700
16. >4700 to ≤4800
17. >4800
42
427
7 Mot
Motor 2 Hi RPM
RPM This
This is a h
his
isttog
ogra
ram
m of the Mot
Motor 2 R
RPM
PM.. The
The sam
sample
ple ti
tim
me is
is ev
ever
ery
y 1.0
1.0 sec-
sec-
onds. All values are in RPM. The histogram breaks the RPM spectrum into
17 buckets, and displays the time that was spent in eac
each h bucket. The buck-
ets are defined as follows:
NUMBER RPM
1. ≤3300
2. >3300 to 3400
3. >3400 to ≤3500
4. >3500 to ≤3600
≤
5
6.. >
>3
36
70
00
0 tto
o ≤3700
3800
7. >3800 to ≤3900
8. >3900 to ≤4000
9. >4000 to ≤4100
10. >4100 to ≤4200
11. >4200 to ≤4300
12. >4300 to ≤4400
13. >4400 to ≤4500
14. >4500 to ≤4600
15. >4600 to ≤4700
16. >4700 to ≤4800
17. >4800
428 – spare
440
114
8. DIAGNOS
DIAGNOSTIC
TIC INFORMATION DISPLAY (DID) PANEL
The DID panel (17FM558) indicates the operating condition of the truck and is a primary troubleshooting aid for
maintenance and service personnel.
The AC OHV propulsion system utilizes the message lines and the function keys on the DID panel (Fig. 61). The
message lines provide propulsion system operating information, test status information, and function key label in-
formati on, depending upon the DID panel’s
formation, panel’s mode of display
display.. The function k
keys
eys assume dif
different
ferent functionali
functionality
ty depend-
ing upon the DID panel’s mode of display.
8.1. MODES DISPLAY
This is the Normal display when there are no active faults and no AC OHV propulsion system tests have been
commanded through the DID panel (Fig. 62).
The display will indicate one of the following modes of operation:
1. REST – The Parking Brake is applied and both the AC OHV propulsion system and the truck are in the appropri-
ate condition for the REST mode to be active.
2. TEST – The AC OHV propulsion system is in a self–test mode of operation.
3. READY – The AC OHV propulsion system is ready for powering.
4. PROPEL – The AC OHV propulsion system is powered up and the Direction Selector switch is either in FOR-
WARD or REVERSE.
5. RETARD – The AC OHV propulsion system is powered up and retard effort is commanded either from the
retard pedal or retard speed control.
MENU/MESSAGE LINE
MENU/MESSAGE LINE SOFT KEYS – SOFT

KEY FUNCTIONS
WILL BE DESCRIBED
F1 F2 F3 F4 F5 IN THE SECTION OF
THIS PUBLICATION
SOFT KEYS
WHERE THEY ARE
USED.
FIG. 61. DID PANEL IDENTIFICATION.
IDENTIFICATION. E–44469B.
115
115
FIG. 62. DID P

PANEL
ANEL EXAMPLE – NORMAL DISPLAY (NO F
FAULTS)
AULTS).. E–45315.
116
8.2. FAULTS D
DIISPLAY
Whenever there are active faults, this is the active DID panel message display (Fig. 63). The DID panel faults
display will show the most recent active fault as well as the number of active faults that are currently stored.
The function keys in the DID panel’s Faults Display mode screen provide the user with the following capabilities:
(Fig. 64)
1. Function
ion key F1 (Up) moves the display UP through the active fault list, thereby displaying detailed information
regarding the fault of interest.
2. Function kke
ey F2 ( Down ) moves the display DOWN through the active fault list, thereby displaying detailed
information regarding the fault of interest.
3. Function k
ke
ey F3 (Return ) returns the user to the previous display.
4. Function ke
key F4 (Reset) enables the user to subsequently perform
perform fault reset functions
functions as follows: (Fig. 65)
a. Pressi
Pressing
ng fu
funct
nction
ion k
key
ey F1 (Reset1) after having pressed function key F4 above will reset the currently dis-
played fault.
b. Pressing
Press
activeing function
function ke
faults. key
y F2 (RESET*) after having pressed function key F4 above will reset ALL the currently
FIG. 63. DID P

PANEL
ANEL MESSAGE EXAMPLE – FAUL
FAULTS
TS DISPLAY
DISPLAY.. E–4531
E–45316.
6.
FIG. 64. DID P
PANEL
ANEL MESSAGE EXAMPLE – FAULTS DISPLAY FUNCTION KEYS. E–45317.
117
117
FIG. 65. DID P

PANEL
ANEL MESSAGE EXAMPLE – FAUL
FAULT
T RESET FUNCTION KEYS. E–45318.
c. Pressing
Pressing funct
function
ion key F5 (cancel) exits the user from the fault reset screen and returns the user to the faults
display screen.
5. Function k
ke
ey F5 displays additional information regarding the currently displayed fault.
8.3. TEST DISPLAY

When function key F4 (MENU) is pressed when the DID panel’s Normal mode display is active, the DID panel’s
Test Display mode appears to the user (Fig. 66).
The function keys in the DID panel’s Test Display mode provide the user with the test capabilities described
FIG. 66. DID P
PANEL
ANEL MESSAGE EXAMPLE – TEST DISPLAY
DISPLAY FUNCTION KEYS. E–45319.
118
FIG. 67. DID P

PANEL
ANEL MESSAGE EXAMPLE – LOAD BOX TEST FUNCTION KEYS. E–45320.
FIG. 68. DID P

PANEL
ANEL MESSAGE EXAMPLE – LOAD BOX TEST DATA.
DATA. E–45321.
8.3.1.
8.3.1. Self Loa
Load
dTTest
esting
ing
Function key F1 (Load Box) displays the Load Box screen to the user (Fig. 66). Commands now available to the
user are as follows:
1. Pres
Pressi
sing
ng fu
func
ncti
tion
on key
key F2 (Enter) requests Load Box mode of operation (Fig. 67). Press F2 to enter the Load-
box mode. With the engine running and the accelerat
accelerator
or pedal fully pressed, the engine net horsepower,
horsepower, the
engine load signal, the AC OHV propulsion system horsepower adjust level, and the ground fault current are
displayed to the user (Fig. 68).
2. Pr
Pres
essi
sing
ng func
functi
tion
on key
key F5 (Return) stops the Load Box Test and returns the user to the top level DID Test
Display mode (Fig. 66).
119
119
FIG. 69. DID P

PANEL
ANEL MESSAGE EXAMPLE – PSC SOFTWARE VERSION DA
DATA.
TA. E–45322.
8.3.2.
8.3.2. Soft
Software
ware Vers
ersion
ion Dis
Display
play
Function key F2 (SW Vers) displays the PSC Software Version that is loaded in the AC OHV propulsion system
(Fig. 66). Subsequent pressing of the F2 (Next) function key will display the following information in the order listed:
1. PSC
PSC s
sof
oftw
twar
are
evver
ersi
sion
on (F
(Fig
ig.. 69)
69)
2. In
Inve
vert
rter
er #1 so
soft
ftwa
ware
re vers
versio
ion
n
3. In
Inve
vert
rter
er #2 so
soft
ftwa
ware
re vers
versio
ion
n
4. TCI
TCI so
soft
ftwa
ware
re ve
vers
rsio
ion
n
5. TCI
TCI bas
base
eccon
onfi
figu
gura
rati
tion
on vers
version
ion
Pressing function key F5 (Return ) at any while in the Software Version display will return the user to the top level
DID panel Test Display mode (Fig. 66).
8.3.3.
8.3.3. Lin
Link
k Capaci
Capacitanc
tance
eTTesti
esting
ng
Pressing function key F3 (Cap Test) will invoke the Link Capacitance Test (Fig. 66). The results of the Link Ca-
pacitance Test are then automatically
automatically displayed (Fig. 70). Commands now available to the user are as follows:
1. Pres
Pressi
sing
ng func
functi
tion
on key F2 (Start) will start the Link Capacitance Test again.
key
2. Pres
Pressi
sing
ng ffun
unct
ctio
ion
n ke
key
y F5 (Return ) will return the user to the top level DID panel Test Display mode (Fig. 66).
3. Pr
Pres
essi
sing
ng func
functi
tion
on key
key F5 (Return ) again will return the user to the DID panel’s Normal mode display screen
(Fig. 62).
120
FIG. 70. DID P

PANEL
ANEL MESSAGE EXAMPLE – LINK CAPACITANCE
CAPACITANCE TEST DAT
DATA.
A. E–45323.
FIG. 71. DID P

PANEL
ANEL MESSAGE EXAMPLE – OVERSPEED SETTING DAT
DATA.
A. E–45324.
8.3.4.
8.3.4. Ove
Overs
rspee
peed
d Set
Settin
ting
g
1. Pressing F4 (Over Speed) displays the Overspeed Settings that are loaded into the AC OHV propulsion sys-
tem (Fig. 71).
2. Pr
Pres
essi
sing
ng fun
funct
ctio
ion
n ke
key
y F5 (Return ) will return the user to the top level DID panel Test Display mode (Fig. 66).
3. Pr
Pres
essi
sing
ng func
functi
tion
on key
key F5 (Return ) again will return the user to the DID panel’s Normal mode display screen
(Fig. 62).
121
122
9. EVENT CODES
WARNING: Lethal Voltages may be present on some circuits. Always turn off and Safety Tag Tag the KEY

SWITCH in the Operator Cab and then verify that ALL lights on either Capacitor Charge Indicating Light
Panel (CCL1 or CCL2) are extinguished before entering the Main Control Cabinet, Retarding Grid Box, or
either Motorized Wheel and/or axle box.
WARNING: When troubleshooting the AC OHV propupropulsion

lsion system, unless stated otherwise, the truck en-
gine should be shutdown
shut down and power removed from the DC link. Keep in mind that at 400 RPM engine
speed, the DC link is commanded to be energized. DO NOT use the REST state to remove power from the
DC link during the troubleshooting of propulsion system circuitry and components.
9.1. EVENT NUMBERS

The event numbers that appear on the DID panel display in the operator’s cab (and the w PTU
PTU Toolbox) consist of
three (3) digits. The source of the event detection information is as ffollows:
ollows:
Event Number Range Event Source

000 through 099 PSC – Propulsion System Controller
100 through 199 Inverter #1
200 through 299 Inverter #2
600 through 699 TCI – Truck Control Interface
9.2
9.2. EV
EVEN
ENT
T RE
REST
STRI
RICT
CTIO
IONS
NS
Each event has an assigned restriction which indicates the limitations, if any, placed on propulsion system opera-
tion when that event is active. A brief description of each event restriction follows:
Restriction Description
NO PROPEL / LOADBOX No Propel (red) light is illuminated in the operator cab. No propulsion effort
is allowed.
mode Retard effort
is restricted. effort and DC link energization is allowed. Load Box
NO POWER No Retard (red) light is illuminated in the operator cab. No propulsion effor

effortt
or retard effort
effort is allowed. The DC link is deenergized.
SPEED LIMIT / SYSWARN Propel System Caution (yellow) light is illuminated in the operator cab.
Propel and Retard effort is allowed. The DC link is energized. A speed limit
restriction is imposed on the truck.
INVER
INVERTER
TER 1 DI
DISAB
SABLE
LE Inve
Invert
rter
er/w
/whe
heel
el moto
motorr #1 is di
disa
sabl
bled
ed.. Li
Limi
mite
ted
d prop
propul
ulsi
sion
on and
and reta
retard
rd effo
effort
rt is
available.
INVER
INVERTER
TER 2 DI
DISAB
SABLE
LE Inve
Invert
rter
er/w
/whe
heel
el moto
motorr #2 is di
disa
sabl
bled
ed.. Li
Limi
mite
ted
d prop
propul
ulsi
sion
on and
and reta
retard
rd effo
effort
rt is
available.
ENGI
ENGINE
NE SPEE
SPEED
D/R
RP
P The
The e
eng
ngin
ine
esspe
peed
ed is rais
aised an
and
d RP1
RP1 is clos
closed
ed in res
espo
pons
nse
e to
to a po
pote
tent
ntia
iall
Retard circuit problem.
SYSEVENT Nhttps://www.besttruckmanuals.com/
o restrictions are imposed; the event is logged for information purposes
only.
TABLE 5 lists all the events for the GE OHV AC propulsion system and their associated restriction levels.
123
FIG. 72. TCI EVENT_MENU SCREENS

9.3.
9.3. TR
TROU
OUBL
BLES
ESHO
HOOT
OTIN
ING
G INFO
INFORM
RMA
ATION
TION
In the following tables, troubleshooting

troubleshooting recommendations are provided
provided for each event. Unless noted otherwise,
perform each step in the order listed until the fault is corrected.
TABLE 5 lists all the events for the GE OHV AC propulsion system and their associated troubleshooting recom-
mendations.
9.4
9.4. EV
EVEN
ENT
T DA
DAT
TA AC
ACCE
CESS
SS
NOTE: The following section

section describes TCI event data access in detail. A similar process is followed for
PSC event data access using the PSC menu and screen hierarchy (refer to Figure 3) for details.
Perform the following to gain access to TCI event data:

PTU Toolbox
Toolbox,,
PTU Toolbox .
2. Fr
From
om the
the w
wind
indow
ow b
bro
rows
wser
er,, sele
select
ct PTU Screens –> TCI –> Special_Tasks –> Event_Menu (Fig. 72).
3. The Event_Menu list of screenshttps://www.besttruckmanuals.com/

is now displayed. Double–click on the desired screen to display it.
124
FIG. 73. TCI EVENT SUMMARY SCREEN. E–44368B.
9.4
9.4.1.
.1. View
iew TCI Ev
Eve
ent Su
Sum
mma
marry Sc
Scrreen
Perform the following to view the TCI Event Summary screen.
1. From the Event_Menu, double–click on TCI Event Summary to select that screen (Fig. 72).
2. The TCI Event Summary screen is now displayed (Fig. 73).
This screen contains the following information for each recorded event:
a. The name
name and number
number for each event
b. The sub–ID
sub–ID fo
forr each event
event.. (Event
(Events
s with o
only
nly one sub–ID will hav
have
e 01 as their sub–ID.)
c. The time
time an
and
d date of the event occurr
occurrence
ence
d. The time and date of the reset of the eve

event
nt (If the event is not reset, tthis
his column will display all z
zeroes
eroes for the
reset time and date.)
3. Close tth
he TCI Event Summary display screen by clicking on the X in the upper right corner of the screen.
125
FIG. 74. TCI TRIGGER DATA

DATA SCREEN. E–45242.
9.4
9.4.2.
.2. View
iew TCI Trigg
igger Da
Datta Sc
Scre
ree
en
Perform the following to view the TCI Trigger Data screen.
1. From the Event_Menu, double–click on TCI Trigger Data to select that screen (Fig. 72).
2. The TCI Trigger Data screen is now displayed (Fig. 74).
The TCI Trigger Data screen is a real time screen, similar
similar to Figure 46. It captures the pro
propulsion
pulsion and truck
system values at the time that the event of interest was detected and logged. This single data capture at the
time of event occurrence is called a “snapshot”. There is one “snapshot” for every event in the TCI summary
list.
3. Close the TCI Trigger Data display screen by clicking on the X in the upper right corner of the screen.
126
FIG. 75. TCI DA

DATA
TA PACKS SCREEN. E–44369B.
9.4.3. View T
TC
CI Data Packs Screen
Data packs are a series of, typically, 100 “snapshots” of the propulsion and truck system real time values taken 50
milliseconds apart. This provides a 5 second long record of propulsion system values before, during, and after an
event occurrence.
There the
Typically, are recurrence
a limited number of available
of an event data packs,
that already and not
has a data every
pack that event will been
has NOT triggerreset,
the recording of a data
will NOT trigger thepack.
cre-
ation of another data pack.
Perform the following to view the TCI Data Packs screen.
1. From the Event_Menu, double–click on TCI Data Packs to select that screen (Fig. 72).
2. The TCI Data Packs screen is now displayed (Fig. 75).
This screen contains the following information for each data pack:
a. The data
data pack
pack num
number
ber
b. The associated
associated event
event numb
number
er and sub–
sub–ID
ID for the dat
data
a pack numbe
numberr
c. The time
time and da
date
te when the dat
data
a pack w
was
as crea
created
ted
d. The time and date of the https://www.besttruckmanuals.com/

d
data
ata pack rreset
eset (If the data pack is reset, it is enable
enabled
d to be o
overwritten
verwritten by the ne
next
xt
event that would trigger a data pack.)
3. Close tth
he TCI Data Packs display screen by clicking on the X in the upper right corner of the screen.
127
FIG. 76. RESET TCI EVENTS SCREEN.

E–45244.
9.5
9.5. RE
RESE
SET
TTTCI
CI EV
EVE
ENT
NTS
SSSCR
CREE
EEN
N
The reset of an event is typically done after the conditions for that event occurrence has been investigated and the
propulsion system is ready to resume normal operation.
Perform the following to view the Reset TCI Events screen.
1. From the Event_Menu, double–click on Reset TCI Events to select that screen (Fig. 72).
2. The Reset TCI Events screen is now displayed (Fig. 76).
3. The user will tthen

hen b
be
e ask
asked
ed if all activ
active
e TCI even
events
ts ar
are
e to b
be
e res
reset.
et. Click on Yes to reset all active TCI events or
No to abort this action.
action. The screen automatically closes upon either selection.
NOTE: When events are reset, their data packs are enabled to be overwritten
overwritten by subsequen
subsequentt events. Re-
set events remain in the event summary list until they are erased, however.
128
FIG. 77. ERASE TCI EVENTS SCREEN.

E–45245.
9.6.
.6. ER
ERAS
ASE
ETTCI
CI EVE
VENT
NTS
SSSCR
CREE
EEN
N
The erasure of event data only affects those events that have been reset. The erasure removes those reset events
from the event summary list, removes their associated “snapshots” and removes their data packs, if present.
Perform the following to view the Erase TCI Events screen.
1. From the Event_Menu, double–click on Erase TCI Events to select that screen (Fig. 72).
2. The Erase TCI Events screen is now displayed (Fig. 77).
3. The user will tthen

hen b
be
e ask
asked
ed if all st
store
ored
d TCI e
event
vents
s are to be eras
erased.
ed. Clic
Click
k on Yes to erase all stored TCI events
or No to abort this action. The screen automatically closes upon either selection.
NOTE: Only events that have been reset will be erased by this action. Events that are not reset will remain
in the event summary, and any associated data packs will remain as well.
9.7.
9.7. EV
EVEN
ENT
TAAND
ND INVE
INVERT
RTER
ER PAR
ARAM
AMET
ETER
ERS
SLLIS
IST
T
A short description of all TCI events, PSC events, and inverter events is provided on the Events & Inv Params
screen. This screen lists all tthe
he events in numerical order and provides a brief description of the event
event.. It can be
accessed from either the PTU_Screens TCI browser or PTU_Screens PSC browser.
Perform the following to access the Events & Inv Params screen:

PTU to the TCI or PSC serial port (located in the operator cab), start the GE OHV w PTU
PTU
Toolbox
oolbox,, enter password, select PSC Panel or TCI Panel, select appropriate truck type, and click on LOGIN to
PTU Toolbox .
w PTU
2. Fro
Fromm tthe
he win
window
dow bro
browse
wserr, sele
select
ct PTU Screens –> TCI or PSC –> Special_Tasks –> Events & Inv Params
(Fig. 72).
3. The Events & Inv Params screen is now displayed (Fig. 78).
4. Click on the
the d
desi
esired
red eve
event
nt lis
listt butt
button
on (PSC Event List, TCI Event List, Inverter Event List) to open. (Use the
scroll bar on the side to navigate through the list).
5. Cl
Clos
ose
e the
the lis
listt by
by cl
clic
ickin
king
g on
on th
the
e X in the upper right corner of the screen.
6. Close tth
he Events & Inv Params display screen by clicking on the X in the upper right corner of the screen.
PTU Tool-
box, shut down the PTU, and disconnect it from the serial port.
129
FIG. 78. EVENTS & INV PARAMS SCREEN. E–44370A.
130
TABLE 5. EVENT CODE DESCRIPTIONS AND INFORMATION

Event Event Restrictions
Detection Information
Description (If Any)
NOTE: Not all faults are prese
present
nt on all propulsion
propulsion systems. Certain faults app
apply
ly to specific propulsion
propulsion systems
only and will only be detected on those propulsion systems.
000–No Fault None No faults present.
002–High Ground Fault NO POWER Ground fault detected.
For voltage < 1000 V, detection threshold is 166 mA
For voltage >= 1000 V, detection threshold ramps from 166 mA at
1000 V down to approximately 70 mA at approximately 1500 V
003–Failed Diode NO POWER Failed diode in main rectifier detected.
004–GF Cutout Not SYS EVENT Generator Field Cut–Out switch (GFCO) moved to cut–out position
Reset while propulsion system not in REST Mode (link is energized).
005–Drive System NO PROPEL A component of the propulsion system, identified by the following
Overtemp sub–ID, exceeded its operational temperature limit:
:01–Auxiliary Blower Control Phase Control Rectifier (AUXPC)

:02–Auxiliary Blower Control Inverter (AUXINV)
:03–Alternator
:03–Alternat or Field Static Exciter (AFSE)
:04–Alternator
:05–Left Wheel motor Stator
:06–Left Wheel motor
motor Rotor
:07–Right Wheel motor Stator
:08–Right Wheel motor Rotor
:09–Chopper Module GTO
:10–Chopper Module Diode
:11–Left Wheel motor Inverter GTO
:12–Left Wheel motor Inverter Diode
:13–Right Wheel motor Inverter GTO
:14–Right Wheel motor Inverter Diode
:15–Rectifierr Diode
:15–Rectifie
006–Both INV Comms NO POWER PSC lost communication with both inverters.
Failed
008–DC Link NO POWER DC link exceeded a voltage limit, identified by the following sub–ID:
Overvoltage
:01–Persistently above a level while not in retard operation
:01–Persistently
:02–Persistently
:02–Persistently above a level while in retard operation
:03–Instantaneously above a level regardless of operating mode
009–Alt Field NO POWER Alternator field current exceeded a limit, identified by tth
he following
Overcurrent sub–ID:
:01–Persistently above a level

:02–Instantaneously above a higher level
:03–With persistence due to low engine speed
011–Retard Lever SYS EVENT The received signal from the Retard Lever exceeded a limit, as iden-
tified by the following sub–ID:
:01–Signal volts too high

:02–Signal volts too low
012–Retard P
Pe
edal B
Ba
ad SYS E
EV
VENT The rre
eceived s
siignal from tth
he Re
Retard P
Pe
edal e
ex
xceeded a limit, as iid
den-
tified by the following sub–ID:
:01 Signal volts too high
:02–Signal volts too low
013–Midvolt Test Failure NO POWER Inverter failed its mid–voltage self test.
131
TABLE 5. EVENT CODE DESCRIP

DESCRIPTIONS
TIONS AND INFORMATION (Cont’d)
Information
014–Analog
Fault Sensor SP
SPEE
EED
D LI
LIMI
MIT
T The recei
eceive
exceeded ved
a dlimit:
sign
signaal fro
rom
m a se
sen
nsor
sor, ide
dent
ntiified
fied by tth
he fo
foll
llow
owiing sub–
sub–IID,
:01–Alternator Field Current

:01–Alternator
:03–Loadbox Current (LDBX)
:04–Alternator 3–Phase Voltage
:05–Alternator Field Volts
:10–PSC Link Voltage
:11–Inverter No. 1 Link Voltage
:12–Inverter No. 2 Link Voltage
Voltage
:13–A2D Ground
:14–A2D Gain
:15–Fault Current
:16–ATOC
:21–DB Grid Blower No. 1 Current
:22–DB Grid Blower No. 2 Current
015–Restrictive Analog NO POWER The received signal from a sensor, identified by the following sub–ID,
Sensor Fault exceeded a limit:
:02–Link Current
016–PSC CPU Card NO POWER A problem occurred with a PSC CPU card task, as identified by the
following sub–ID:
:01–Task 1 failed to initialize

:07–Maintenance task failed to initialize
:09–FLASH CRC computation did not match expected value
:10–BRAM CRC computation did not match expected value
:11–Tasks took too long to initialize
:12–BBRAM data pack pointers corrupted
017–PSC Digital I/O NO POWER PSC CPU lost communication with the FB104 PSC digital I/O card.
Card Fault
018–PSC Analog I/O NO POWER PSC CPU lost communication with the FB143 PSC analog I/O card,
Card Fault as further identified by the following sub–ID:
:01–PSC Analog I/O card missing

:02–PSC Analog I/O communication timed out
019–Riding R
Re
etard P
Pe
edal SYS E
EV
VENT Brake a
an
nd P
Prropel P
Pe
edal si
signals si
simultaneously re
received a
an
nd ttrruck
speed greater than 5 mph.
020–High Torque NO PROPEL Low speed torque limit exceeded.
Timeout
021–TCI Comm Fault NO PROPEL PSC lost or received corrupted communication from TCI, as further
identified by the following sub–ID:
:01–Message Missing
:02–Bad Tick
:03–Bad CRC
:04–Overflow
:05–Bad Start
:06–Bad Stop
132

DESCRIPTIONS
Information
022–Persistent
Comm Fault TCI NO P
PO
OWER PSC dde
etected ppe
ersistent llo
ost o
orr c
co
orrupted c
co
ommunication ffrrom TC
TCI
over a period of time with truck stopped.
023–Tertiary Overcurrent NO POWER Alternator field tertiary current limit exceeded.
024–PSC Config File NO POWER Incorrect or missing PSC configuration file detected, as further identi-
fied by the following sub–ID:
:01–Configuration file not loaded

:01–Configuration
:02–Configuration
:02–Configuration file CRC computation failed
:03–Configuration
:03–Configuration file has incorrect major release number
:04–Overspeed values in configuration file are incorrectly set.
025–Aux
Aux B
Bllower S
Sy
ystem NO P
PO
OWER Problem w wiith tth
he au
auxiliary bl
blower c
co
ontrol sy
system d
de
etected, a
as
s ffu
urther
:01–Auxiliary blower control speed feedback indicates no or incorrect

blower speed
:02–Frequent auxiliary blower control fault shutdowns
026–Cap O
Ov
verpressure NO P
PO
OWER Filter ca
capacitor o
ov
verpressure fa
failure de
detected, a
as
s fu
further iid
dentified b
by
y
the following sub–ID:
:01–Inverter No. 1 filter cap overpressure

:02–Inverter No. 2 filter cap overpressure
027–Panel Not NO POWER One of PSC panel connectors not connected properly. Further identi-
Connected at Power fied by the following sub–ID:
Up
:01–CNFB
:02–CNI/CNX (3500 HP
HP,, 150 T
Ton)
on)
:03–Aux blower connector
030–GF Contactor SPEED LIMIT GF contactor command and feedback do not agree.
031–Battery Boost SPEED LIMIT GFR contactor ffaailed to open or close when commanded. Further
Circuit identified by the following sub–ID:
:01–GFR
:02–GFR failed
failed to
to open
close
:03–SCR3 failed
032–RP C
Co
ontactor SPEED L
LIIMIT & STUCK RP1 contactor command and feedback do not agree. Further identi-
RP fied by the following sub–ID:
:01–RP1
:02–RP2
:03–RP3
033–Retard Circuit SPEED LIMIT & S
ST
TUCK
RP
035–Engine Speed SPEED LIMIT Engine speed signal exceeded upper or lower limit.
Sensor
036–GY19 Grid Blower NO POWER Grid blower failure detected, further identified by the following sub–
ID:
:01–Grid blower no. 1 stalled
:02–Grid blower no. 2 stalled
:03–Grid blower no. 1 open
:04–Grid blower no. 2 open
:05–Excessive difference between grid blower motor currents
133

DESCRIPTIONS
Information
037–Computer
Supply Power SPEED L
LIIMIT Computer PoPower S Su
upply vo
voltages ex
exceeded u
up
pper or
or llo
ower lliimit,
further identified by the following sub–ID:
:01–5 V DC positive
:02–15 V DC positive
:03–15 V DC negative
040–Volts 24 Positive SPEED LIMIT +24V Power Supply exceeded upper or lower limit.
041–Volts 24 Negative SPEED LIMIT –24V Power Supply exceeded upper or lower limit.
042–Direction NO PROPEL Forward o
orr Re
Reverse Sw
Switch c
co
ommand rre
eceived w
wh
hile iin
nSSe
elfload
Requested During Mode of operation.
Selfload
043–Propulsion Battery SPEED LIMIT Propulsion system battery voltage below low limit.
Voltage Low
044–Propulsion Battery SYS EVENT Propulsion system battery voltage above high limit.
Voltage High
045–Chopper Open SP
SPEE
EED
D LI
LIMI
MIT
T Cho
hoppper
per Mod
Module
ule fa
fail
iled
ed du
duri
rin
ng chop
choppe
perr self
self te
test
st,, furt
urthe
herr iide
dent
ntif
ifie
ied
d by
Circuit the following sub–ID:
:01–Chopper 1
:02–Chopper 2
046–Re
046–Retar
tard
d Sh
Short
ort Cir
Circui
cuitt SPE
SPEED
ED LLIMI
IMIT
T & EN-
EN- Failure during chopper self test.
test. Link voltage decayed too quickly
quickly
GINE SPD when AFSE command set low, prior to starting test.
047–Engine Stall NO POWER Engine stall condition detected.
048–Shorted DC Link NO POWER System detected a potential short on the DC link while attempting to
During Startup charge link.
051–Tach L
Le
eft Re
Rear INV1 D
DIISABLE Problem o occcurred w
wiith ta
tach on
on le
left rre
ear wh
wheelmotor, ffu
urther de
defined
by the following sub–ID:
:01–Tach
:01–Tach signal indicating zero wheel movement when others are
indicating movement
:02–Tach
:02–Tach signal indicating wheel movement when others are
indicating zero movement
052–Tach R
Riight R
Re
ear INV2 D
DIISABLE Problem o occcurred w
wiith tach on
on rriight rear wh
wheelmotor, further de
defined
:01–Tach
indicating movement
:02–Tach
053–Tach Left Front SYS EVENT Problem occurred with tach on left front wheelmotor, further defined
:01–Tach
indicating movement
:02–Tach
134

DESCRIPTIONS
Information
054–Tach R
Riight F
Frront SYS E
EV
VENT Problem o occcurred w
wiith ta
tach on
on rriight ffrront w
wh
heelmotor, ffu
urther d
de
efined
:01–Tach
indicating movement
:02–Tach
055–Front Wheel Tachs SYS EVENT Problem occurred with tachs on front wheel motors.
056–Inverter Software SYS E
EV
VENT Incorrect version of Inverter S
So
oftware iis
s iin
nstalled. Further iid
dentified
Version by the following sub–ID:
:01–Inverter #1
:02–Inverter #2
061–Motor Overspeed SYS EVENT Truck exceeded motor overspeed limit.
063–Engine Load Signal SYS EVENT The Engine Load Signal feedback from the engine controller is out-
Fault side of limit, further defined by the following sub–ID:
:01–Below minimum value

:02–Above maximum value
:03–PWM signal failed low
:04–PWM signal failed high
:05–PWM signal failed incorrect period
065–Analog Input Range SPEED LIMIT
LIMIT (10 MP
MPH)
H) Analo
Analogg input ou
outsid
tside
e its desi
design
gn rang
range,
e, furt
further
her iden
identifi
tified
ed by the fo
follow-
llow-
Check ing sub–ID:
:01–Auxiliary blower control phase controller temperature

:02–Auxiliary blower control inverter temperature
:03–Alternator
:03–Alternator field static exciter temperature
:04–Alternator
:04–Alternator temperature
:05–Left rear wheelmotor stator temperature
:06–Left rear wheelmotor rotor temperature
:07–Right rear wheelmotor stator temperature
:08–Right rear wheelmotor rotor temperature
:09–Chopper module GTO temperature
:10–Chopper module diode temperature
:11–Left rear wheelmotor inverter GTO temperatur
temperature
e
:12–Left rear wheelmotor inverter diode temperature
:13–Right rear wheelmotor inverter GTO temperature
:14–Right rear wheelmotor inverter diode temperature
:15–Rectifierr diode temperature
:15–Rectifie
070–Link Capacitance SYS EVENT Link capacitance low, but acceptable for operation.
Low Caution
NOTE:
Nominal for 17KG498D2
17KG498D2 and newer control:
control: 21600 uF
17KG498D1 and earlier control:
control: 24000 uF
Event declared when measurement below:
below: 15000 uF
Nominal for 17KG527 control:
control: 13500 uF
Event declared when measurement below: 7875 uF (527 group)
group)
135

DESCRIPTIONS
Information
071–Link Capacitance SPEED LIMI
LIMIT
T (10 MPH)
MPH) Link c
capaci
apacitance
tance below accep
acceptabl
table
e limit
limit for n
normal
ormal opera
operation.
tion.
Low Warning
NOTE:
17KG498D2 and newer control:
control: 21600 uF
17KG498D1 and earlier control:
control: 24000 uF
Event declared when measurement below:
below: 12500 uF
Nominal for 17KG527 control:
control: 13500 uF
Event declared when measurement below: 7875 uF (527 group)
group)
072–
072–Gr
Grou
ound
nd Ci
Circ
rcui
uitt SP
SPEE
EED
DLLIM
IMIT
IT (10
(10 M
MPH
PH)) Prob
Proble
lem
mddet
etec
ecte
ted
dwwit
ith
h gro
groun
und
d fau
fault
lt de
dete
tect
ctio
ion
n cir
circu
cuit
it whic
which
h is
is ttyp
ypic
ical
ally
ly
associated with failure of the filter capacitor test to discharge the ca-
pacitors within 30 seconds.
074–Inverter1 Comm INV
NV1
1 DIS
DISAB
ABL
LE Com
ommumuni
nic
cat
atio
ionn at
attem
emppt wit
with
h IIn
nvert
verter
er #1 tim
time
ed ou
out. IIn
nvert
verter
er 1 not
not cu
cut-
t-
Failed out. Further identified
:01–No communication Inverter #1

:02–Inverter #1 customer option bit
075–Inverter 2 Comm INV
NV2
2 DIS
DISAB
ABL
LE Com
ommumuni
nic
cat
atio
ionn at
attem
emppt wit
with
h IIn
nvert
verter
er #2 tim
time
ed ou
out. IIn
nvert
verter
er 2 not
not cu
cut-
t-
Failed out. Further identified
:01–No communication Inverter #2

:02–Inverter #2 customer option bit
076–FB173 Card NO POWER A failure in the FB173 card was detected, further identified by the
following sub–ID:
:01–Speed FPGA did not download correctly

:02–Speed count update not changing
:03–Alternator FPGA did not download correctly
:04–Microcontroller
:04–Microcontroller SRAM did not program
:05–Slow task counter is less than minimum value
:06–Medium task counter is less than minimum value
:07–Fast task timer is less than minimum value
:08–FD task timer is less than minimum value
:09–Link current
:10–Alternator valuetimed
FPGA is outout
of limits
077–Inverter Failed VI NO POWER Inverter 1 or Inverter 2 failed during VI test. System forced to link
Test discharged state. System resets and attempts test sequence again.
Does not lock out; other inverter is allowed to pass, or user can cut
out failed inverter.
078–Inverter Background SYS EVENT A failure in the inverter background comm
mmu unication was detected.
Communication Further identified by the following sub–ID:
s ub–ID:
Failure
:01–Inverter #1
:02–Inverter #2
084–Control Power SYS EVENT Loss of control power switch feedback while truck moving.
Switch
085–Auxiliary Cooling SYS E

EV
VENT Problem d de
etected wwiith au
auxiliary bl
blower co
control sy
system, further iid
denti-
Fault fied by the following sub–ID:
:02–Auxiliary blower motor speed signal out of range
:03–Excessive difference between auxiliary blower motor speed
feedback and auxiliary blower motor speed command
:04–Abnormal shutdown of auxiliary blower control system
136

DESCRIPTIONS
Information
087–HP Low SYS EVENT Propulsion system adjusted HP load on engine has been reduced to
its minimum value for an excessive period of time.
088–HP Limit SYS EVENT Excessive propulsion system demand on available engine HP, fur-
ther identified by the following sub–ID:
:01–Propulsion system HP demand in propel mode exceeds

available engine HP for a persistent period of time
:02–Propulsion system HP demand in propel or ready mode could
result in engine stall
089–Engine Speed SYS EVENT Engine speed does not match engine command, further identified by
Command the following sub–ID:
:02–Allowable difference between engine command and actual

engine speed exceeded
091–Inverter 1 cutout SYS EVENT Inverter 1 is cutout.
092–Inverter 2 cutout SYS EVENT Inverter 2 is cutout.

094–Illegal L
Liimp Mo
Mode SYS E
EV
VENT Limp Mo
Mode rreequested (i.e. inverter 1 or 2 cutout switch a
ac
ctuated)
when truck is moving.
095–Bad BRAM Battery SYS EVENT BRAM battery voltage below acceptable limit.
096–Unexpected System SYS EVENT PSC CPU reset detected without reset request.
Reset
098–Data Store SYS EVENT PSC data store commanded via PTU.
NOTE: Faults 100 – 199 as shown in th this
is table apply to Inverter #1. The same respective
respective faults, 200 – 299 (not
shown in this table) apply to Inverter #2. For Example, Fault 100 is an Inverter #1 CPU Card Restrictive fault
fault and
Fault 200 is an Inverter #2 CPU Card Restrictive fault.
100–Inverter 1/2 CPU INV 1/2 OFF SPEED Restrictive Inverter 1/2 CPU card problem detected.
Card Restrictive LIMIT (10 MPH)
101–Inverter 1/2 CPU INV 1/2 OFF SPEED Non–Restrictive Inverter 1/2 CPU card problem detected.
Card LIMIT (10 MPH)
Non–Restrictive
102–Inverter 1/2 I/O INV 1/2 OFF SPEED Restrictive Inverter 1/2 I/O card problem detected.
Card Restrictive LIMIT (10 MPH)
103–Inverter 1/2 CPU SYS EVENT Non–Restrictive Inverter 1/2 I/O card problem detected.
Card
Non–Restrictive
104–Inverter 1/2 Fiber INV 1/2 OFF SPEED Inverter 1/2 fiber optic card problem detected.
Optic Card LIMIT (10 MPH)
105–Inverter 1/2 Power INV 1/2 OFF SPEED Inverter 1/2 power supply card problem detected.
Supply Card LIMIT (10 MPH)
106–Inverter 1/2 DC INV 1/2 OFF SPEED DC power wiring problem detected, further defined by the following
Power Wiring LIMIT (10 MPH) sub–ID:
:01–DC power connection open

:02–Link and phase voltage mismatch
107–Inverter 1/2 Gate SYS E
EV
VENT Inverter 1/
1/2 g
ga
ate d
drrive p
po
ower s
su
upply pr
problem de
detected.
Drive Power Supply
109–Inverter 1/2 Link INV 1/2 OFF SPEED Inverter 1/2 link voltage sensor problem detected.
Voltage Sensor LIMIT (10 MPH)
137

DESCRIPTIONS
Information
111–Inverter 1/2 Input INV 1/2 OFF SPEED Inverter 1/2 input filter voltage sensor problem detected.
Filter Voltage Sensor LIMIT (10 MPH)
113–General Inverter 1/2 INV 1/2 OFF SPEED Inverter 1/2 phase current or voltage unbalance or exceeded limit
Restrictive LIMIT (10 MPH) detected.
114–General Inverter 1/2 SYS E
EV
VENT Inverter 1/
1/2 eellectrical noise d
de
etected on
on s
siignal ch
channels o
orr o
op
peration-
Non–Restrictive al voltage limits exceeded.
115–Inverter 1/2/System
115–Inverter INV 1/2 OFF SPEED Inverter#1/System Controller interface problem detected such as
Controller Interface LIMIT (10 MPH) inconsistent commands, loss of communication, or sensor signals
beyond limits.
116–In
16–Inverte
verterr 1/
1/2
2 Phase
Phase A INV 1/2 OFF SPEED Inverter#1 Phase A problem detected such as GTO failure to follow
LIMIT (10 MPH) command or Phase A overcurrent.
117–Inverter 1/2 Phase A INV 1/2 OFF SPEED
117–Inverter Restrictive Inverter#1 Phase A Positive (+) problem detected such as
Positive (+) LIMIT (10 MPH) module failure to follow command.
Restrictive
118–Inverter 1/2 Phase A SYS EVENT

118–Inverter Non–Restrictive Inverter#1 Phase A Positive (+) problem detected.
Positive (+)
Non–Restrictive
119–Inverter 1/2 Phase A INV 1/2 OFF SPEED
119–Inverter Restrictive Inverter#1 Phase A Negative (–) problem detected such
Negative (–) LIMIT (10 MPH) as module failure to follow command.
Restrictive
120–Inverter 1/2 Phase SYS EVENT Non–Restrictive Inverter#1 Phase A Negative (–) problem detected.
A Negative (–)
Non–Restrictive
121–Inverter 1/2 Phase INV 1/2 OFF SPEED Inverter#1 Phase A current sensor or Phase A current problem de-
A Current LIMIT (10 MPH) tected.
123–Inverter 1/2 Phase INV 1/2 OFF SPEED Inverter#1 Phase A voltage sensor or Phase A voltage problem de-
A Voltage LIMIT (10 MPH) tected.
125–Inverter 1/2 Phase INV 1/2 OFF SPEED Inverter#1 Phase B problem detected such as GTO failure to follow
B LIMIT (10 MPH) command or Phase B overcurrent.
126–Inverter 1/2 Phase INV 1/2 OFF SPEED Restrictive Inverter#1 Phase B Positive (+) problem detected such as
B Positive (+) LIMIT (10 MPH) module failure to follow command.
Restrictive
127–Inverter 1/2 Phase SYS EVENT Non–Restrictive Inverter#1 Phase B Positive (+) problem detected.
B Positive (+)
Non–Restrictive
128–Inverter 1/2 Phase INV 1/2 OFF SPEED Restrictive Inverter#1 Phase B Negative (–) problem detected such
B Negative (–) LIMIT (10 MPH) as module failure to follow command.
Restrictive
129–Inverter 1/2 Phase SYS EVENT Non–Restrictive Inverter#1 Phase B Negative (–) problem detected.
B Negative (–)
Non–Restrictive
130–Inverter 1/2 Phase INV 1/2 OFF SPEED Inverter#1 Phase B current sensor or Phase B current problem de-
B Current LIMIT (10 MPH) tected.
132–Inverter 1/2 Phase INV 1/2 OFF SPEED Inverter#1 Phase B voltage sensor or Phase B voltage problem de-
B Voltage LIMIT (10 MPH) tected.
134–Inverter 1/2 Phase INV 1/2 OFF SPEED Inverter#1 Phase C problem detected such as GTO failure to follow
C LIMIT (10 MPH) command or Phase C overcurrent.
138

DESCRIPTIONS
Information
135–Inverter 1/2 Phase INV 1/2 OFF SPEED Restrictive Inverter#1 Phase C Positive (+) problem detected such as
C Positive (+) LIMIT (10 MPH) module failure to follow command.
Restrictive
136–Inverter 1/2 Phase SYS EVENT Non–Restrictive Inverter#1 Phase C Positive (+) problem detected.
C Positive (+)
Non–Restrictive
137–Inverter 1/2 Phase INV 1/2 OFF SPEED Restrictive Inverter#1 Phase C Negative (–) problem detected such
C Negative (–) LIMIT (10 MPH) as module failure to follow command.
Restrictive
138–Inverter 1/2 Phase SYS EVENT Non–Restrictive Inverter#1 Phase C Negative (–) problem detected.
C Negative (–)
Non–Restrictive
141–Inverter 1/2 Phase INV 1/2 OFF SPEED Inverter#1 Phase C voltage sensor or Phase C voltage problem de-
C Voltage LIMIT (10 MPH) tected.
143–Inverter 1/2 Tach 1 INV 1/2 OFF SPEED Restrictive Inverter#1 Tach
Tach 1 signal problem detected.
Restrictive LIMIT (10 MPH)

144–Inverter 1/2 Tach 1 SYS EEV
VENT Non–Restrictive Inverter#1 Tach 1 signal problem d
de
etected.
Non–Restrictive
145–Inverter 1/2 Tach 2 SYS EVENT Restrictive Inverter#1 Tach 2 signal problem detected.
Restrictive
146–Inverter 1/2 Tach 2 SYS E
EV
VENT Non–Restrictive Inverter#1 Tach 2 signal problem d
de
etected.
Non–Restrictive
148–Inverter 1/2 INV 1/2 OFF SPEED Inverter#1 Chopper 1 operational problem detected.
Chopper 1 LIMIT (10 MPH)
150–Inverter 1/2 INV 1/2 OFF SPEED Inverter#1 Chopper 2 operational problem detected.
Chopper 2 LIMIT (10 MPH)
151–Inverter 1/2 Tach INV 1/2 OFF SPEED Excessive difference between Inverter 1/2 Tachs 1 and 2.
Differential LIMIT (10 MPH)
153–Inverter 1/2 Motor INV 1/2 OFF SPEED Inverter 1/2 detected a motor connection problem further defined by
Restrictive LIMIT (10 MPH) the following sub–ID:
:01–Motor connection open

:02–Motor connection short
154–Inverter 1/2 Motor SYS E
EV
VENT Inverter 1/
1/2 d
de
etected a motor tte
emperature exceeding iitts lilimit further
Non–Restrictive defined by the following sub–ID:
:01–Motor rotor temperature high

:02–Motor stator temperature high
155–Second Load SYS EVENT Inverter 1/2 detected a second open load connection.
Connection Open
139

DESCRIPTIONS
Information
601–TCI CPU Card NO PROPEL A problem was detected with the TCI CPU card, further identified by
FB144 the following sub–ID:
:01–10 msec task failed to initialize

:06–50 msec fault manager task failed to initialize
:07–Flash CRC computation did not match expected value
:09–Maintenance task failed to initialize
:10–Upon power–up, excessive bus time outs occurred
:1
:11–Upon
1–Upon power–up, the status of key memory data in BBRAM was
found to be invalid
:12–CRC on protected areas of BBRAM did not match expected
value
602–FB104 TCI Digital NO PROPEL A problem was detected with the TCI digital I/O card.
I/O Card
603–FB160 TCI Analog NO PROPEL A problem was detected with the TCI analog I/O card.
I/O Card
604–TCI to PSC RS422 SPEED LIMIT
LIMIT ((10
10 MPH) Seria
Seriall link co
communi
mmunicati
cation
on wit
with
h PSC was llost
ost fo
forr a persi
persistent
stent time
Comm period, further identified by the following sub–ID:
:01–Missing message
:02–Bad tick
:03–Bad CRC
:04–FIFO overflow
:05–Bad start bit
:06–Bad stop bit
605–Aux Comm Fault None Serial link communication with the Auxiliary Blower Control System
was lost for a persistent time period.
607–
607–Po
Posi
siti
tive
ve 5 vol
volts
ts SP
SPEE
EED
DLLIM
IMIT
IT (10
(10 M
MPH
PH)) +5
+5V
VPPow
ower
er Su
Supp
pply
ly exce
exceed
eded
ed limi
limits
ts fo
forr a pers
persis
iste
tent
nt peri
period
od of time
time..
60
608–
8–Po
Posi
siti
tive
ve 15 Vol
Volts
ts SPEE
SPEED
DLLIM
IMIT
IT (10
(10 MPH
MPH)) +15V
+15V Po
Powe
werr Supp
Supply
ly ex
exce
ceed
eded
ed limi
limits
ts..
609–
609–Ne
Nega
gati
tive
ve 15 Vol
olts
ts SP
SPEE
EED
D LI
LIMI
MIT
T ((10
10 MP
MPH)
H) –15V
–15V Powe
Powerr Sup
Suppl
ply
y exc
excee
eede
ded
d llim
imit
its.
s.
61
610–
0–Po
Pott Ref
Refer
eren
ence
ce SP
SPEE
EED
D LI
LIMI
MIT
T (10
(10 MPH)
MPH) Po
Pott Re
Reffer
ere
enc
nce
e ex
exce
cee
ede
ded
d limi
limitts.
61
613–
3–An
Anal
alog
og In
Inpu
putt SPEE
SPEED
DLLIM
IMIT
IT (10
(10 MPH
MPH)) An an
anal
alog
og sign
signal
al in
inpu
putt o
on
n tthe
he an
anal
alog
og I/
I/O
O car
card
deexc
xcee
eede
dedd iits
ts limi
limits
ts fo
forr
a persistent period of time, as defined by the following sub–ID:
:01–Ground (A2D)
:02–Gain Check (A2D)
614–Battery Separate SYS EVENT The battery separate contactor failed to operate in an expected man-
Contactor ner as further defined by the following sub–ID:
:01–Battery separate failure

:02–Crank battery > control battery
:03–Control battery > crank battery
616–Simultaneous NO PROPEL Simultaneous receipt of forward and reverse direction commands.
Forward and
Reverse Command
140

DESCRIPTIONS
Information
617–Engine Start SYS EVENT The engine start request was denied for the following reason defined
Request Denied by the sub–ID:
:01–Engine warning signal received during cranking

:02–Engine Kill signal received during cranking
619–Engine W
Wa
arning NO P
PR
ROPEL The e
en
ngine wwa
arning s
siignal wa
was re
received w
wh
hen tth
he e
en
ngine s
sp
peed iis
s
above the run threshold.
620–Engine Kill while NO P

PR
ROPEL The e
en
ngine k
kiill si
signal wa
was re
received w
wh
hile tth
he ttrruck w
wa
as m
mo
oving.
Moving
622–Park Brake NO PROPEL Unexpected park brake operation defined by the following sub–ID:
:01–Park brake command and feedback do not agree

:02–Park brake set feedback received while truck moving
623–Hydraulic Brake SYS EVENT The hydraulic brake fluid temperature signal exceeded its maximum
limit, further defined by the following sub–ID:

:01–Tank
:02– Left Front Outlet
:03– Right Front Outlet
:04– Left Rear Outlet
:05– Right Rear Outlet
624–Body Up and SPEED LIMIT

LIMIT ((10
10 MPH) Simul
Simultane
taneous
ous receipt
receipt of b
both
oth fu
fullll payl
payload
oad and b
body
ody up si
signals
gnals ffor
or a
Payload Indication persistent time period.
625–Extended Battery None Excessive time has elapsed between battery separate and subse-
Reconnect Time quent battery reconnection.
628–Connected SYS EVENT Battery volts exceeded limit

mits for a persistent period of time,
me, while
Batteries engine speed is greater than idle and control power is ON; further
defined by the following sub–ID:
:01–Control battery volts below 20 V DC

:02–Control battery volts above 32 V DC
:03–Cranking battery volts below 20 V DC
:04–Cranking battery volts above 32 V DC
629–Barometric SYS EVENT Barometric pressure sensor signal exc xceeeded limits for a persistent
Pressure period of time, further defined by the following sub–ID:
:01–Barometric pressure sensor value too low

:02–Barometric pressure sensor value too high
630–Motor Blower SP
SPEE
EED
D LIMI
IMIT Mo
Moto
torr blo
blower
wer pre
ress
ssur
ure
e sign
signal
al excee
xceedded lim
imit
its,
s, indi
indica
catting
ing a pro
rob
blem
lem
Pressure with the sensor,
sensor, duct work, or axle box sensor. Further defined by
the following sub–ID:
:01–No cooling air

:02–Low voltage
:03–High voltage
:04–Sensor reversed
631–Ambient SYS EVENT Ambient temperature sensor signal exceeded limits for a persistent
Temperature period of time, further defined by the following sub–ID:
:02–Ambient temperature signal too high
141

DESCRIPTIONS
Information
632–TCI Configuration NO PROPEL A problem with the TCI configuration file has been detected, further
File defined by the following sub–ID:
:01–File not loaded

:02–File loaded improperly,
improperly, resulting in bad CRC
:03–Wrong version of file loaded
633–BBRAM Battery SYS E
EV
VENT Battery–backed RAM (BBRAM) battery has failed.
Failure
634–Truck Overloaded NO PROPEL Truck operation restricted when overloaded signal received and TCI
Restrictive configured for restrictive response.
635–Truck Overloaded SYS EVENT Truck operation not restr
stricted when ove
verrloaded sig
signal received and
Non–Restrictive TCI configured for non–restrictive response.
636–Aux Inverter Faults SYS EVENT Auxiliary blower control failure has occurred.
:00–No fault condition; initial state on application of control power

:01–Low DC bus voltage detected during powerup
:02–High DC bus voltage detected during operation
:03–Overcurrent condition detected during operation
:06–High DC bus voltage detected after phase controller powerup
:07–Low DC bus voltage detected after phase controller powerup
:09–Overcurrent condition detected after phase controller powerup
:10–Sustained current overload exists (above rated conditions but
below component safe operating range)
:11–Overcurrent fault due to low DC link voltage
:12–Sustained current overload fault due to low DC link voltage
:13–IGBT protection circuit detected overcurrent
:14–Low or missing AC input voltage detected
638–Engine cranking SYS E
EV
VENT The diesel engine was cr
cranking longer than the maximum allowed
timeout cranking time.
639–Engine Start SYS E
EV
VENT An En
Engine SSttart R
Re
equest wa
was rre
eceived wh
while tth
he d
diiesel e
en
ngine w
wa
as
Request While running. The engine speed must be greater
greater than 600 rpm and the
Running start request signal must be present for three seconds minimum for
this event to be logged.
640–Accel Pedal Too NO PROPEL Accelerator Pedal input is greater than the maximum
mum value for a spe-
High cified period of time.
641–Accel Pedal Too SYS E
EV
VENT Accelerator PPeedal in
input is
is le
less th
than tth
he m
miinimum v
va
alue ffo
or a speci-
Low fied period of time.
696–Unexpected CPU SYS E
EV
VENT The TCI CPU was reset while the system was in Self Load, Propel,
Reset Retard, or Ready mode.
698–PTU Data Store SYS EVENT The DATASTORE command was received by the TCI. No corrective
action required.
However, if DATASTORE was not commanded and the event was
logged, check DATASTORE switch and wiring.
142
10. SPECIAL OPERATIONS AND TESTS
10.1
10.1.. WE
WELD
LDIN
ING
G ON TH
THE
E TR
TRUC
UCK
K
When welding on trucks equipped with GE control panels, connect the welder’s ground cable such that welding
current does not flow through the truck’s control
control wires or cables. This ground connection should be made directly to (or
(or
as close as possible to) the part being welded. For example, if welding is being done on the deck, connect the ground
directly to the deck – not to the control
control box or cab. If welding is being done on the control box door,
door, connect the ground
to the control box door – not to the box frame.
Extreme care should also be taken to prevent electrical current from passing through bearings in the alternator or
motorized wheel motors as this will result in bearing damage and premature bearing failure.
DO NOT pull any control cards or remove panel connectors.

connectors. This practice can cause more damage tthan
han it pre-
vents. It puts unnecessary cycles on the
the connector pins and may cause loose or dirty
dirty pins which could result in a
control system failure.
10.2.
10.2. MOV
MOVING
ING T
TRUC
RUCK
K WIT
WITH
H ONE W
WHEE
HEEL
L MO
MOTO
TOR
R
WARNING: The following procedure is intended for use under emergency or unusual conditions only
and should not be used in lieu of proper troubleshooting and/or maintenance procedures. In any case,
extreme caution must be exercised and all standard safety procedures employed.
employed. When using this “spe-
cial” procedure, the entire procedure should be read before proceeding.
The following procedure should be followed when it has been determined that either one inverter or one wheel
motor is faulty, and the truck must be moved for servicing using the single, operational inverter/wheel motor.
NOTE: Truck speed is limited to 10 mph by the propulsion system when operating with o
only
nly one wheel
motor.
1. With truck stopped

stopped and tthe
he engi
engine
ne runn
running,
ing, ap
apply
ply the Parking Brake (propulsion
(propulsion system
system comman
commanded
ded to REST
mode) and place the Direction Selector handle in the NEUTRAL position.
CAUTION: Single inverter/wheel

CAUTION: inverter/wheel motor operation of the truck should only be done with an empty truck.
Operation of a loaded truck with one inverter/wheel moto
motorr may result in damage to that wheel motor.
2. Remove
Remove the load,
load, iiff pr
prese
esent,
nt, from
from th
the
e tr
truck
uck..
3. On the right sside

ide of the
the main control
control ca
cabinet,
binet, move th
the
e aff
affected
ected in
inverte
verterr cutou
cutoutt switch tto
o the CUTOUT position
position..
This will disable that inverter/wheel motor combination from either accelerating or retarding the truck.
4. Release
Release the
the Parking
Parking Brake (prop
(propulsion
ulsion syste
system
m exits
exits REST mode).
mode).
5. Place the
the Direction
Direction Selector
Selector handle in FORWARD
FORWARD and mo
move
ve the ttruck
ruck tto
o the de
desired
sired locati
location.
on.
143
10.3.. VOL
10.3 VOLT
TAGE A
ATTEN
TTENUA
UATION
TION MODUL
MODULE
E (VA
(VAM)
M) CHECKS
With all wiring removed from the suspect VAM, check that a nominal resistance of 2 Megohms exists between the
points in the charts below.
below. Resistance to ground or to any other points on the V
VAM
AM should be infinite. Refer to the
receptacle and plug diagrams in the system schematic for connector arrangement.
VAM1 AND VAM2, 17FM702, 8 CHANNELS

High
igh Volta
tag
ge Stud Low Voltag
tage Connec
ecto
torr
VH1 CN1–5
VH2 CN1–6
VH3 CN1–10
VH4 CN1–14
VH5 CN1–7
VH6 CN1–3
VH7 CN1–2
VH8 CN1–1
VAM1 AND VAM2, 17FM681, 5 CHANNELS

High
igh Volta
tag
ge Stud Low Voltag
tage Connec
ecto
torr
VH1 CN1–1
VH2 CN1–2
VH3 CN1–3
VH4 CN1–4
VH5 CN1–5
10.4.
10.4. CUR
CURREN
RENT
T ME
MEASU
ASURIN
RING
G MOD
MODULE
ULE C
CHEC
HECKS
KS
With all wiring removed from the suspect current measuring module, the following are the nominal resistance val-
ues between the connection points indicated:
 Between + and – : greater than 20 Kohm
 Between M and + : greater than 1 Megohm
 Between M and – : greater than 1 Megohm
144
10.5.
10.5. LIN
LINK
K CA
CAP
PACI
ACIT
TANC
ANCE
E TE
TEST
ST
The main propulsion DC link capacitance test can be performed through the DID panel (refer to Section 8.3.3.,
Link Capacitance Testing ) provided that truck conditions permit this test. Those conditions are as follows:
1. En
Engin
gine
e ru
runn
nnin
ing
g an
and
d DC llin
ink
k char
charge
ged.
d.
2. Truck
Truck st
stopped
opped with
with no d
direct
irection
ion commanded
commanded and acc
accelerat
elerator
or pedal
pedal not pr
pressed.
essed.
When the DC link capacitance test is run, the AC OHV propulsion system commands the DC link to be charged to
operating level and then it monitors its decay rate from that level. This decay rate is then used to calculate the amount
of DC link capacitance.
The DC link capacitance test can be monitored and its results viewed on a w PTU
PTU screen. This screen can be
accessed as follows:

PTU Toolbox
Toolbox,,
enter password, select PSC Panel, select appropriate truck type, and click on LOGIN to w PTU
PTU Toolbox .
2. From
From (Fig.
Test tthe
he w
wind
indow
79). ow b
bro
rows
wser
er,, se
sele
lect
ct PTU Screens –> PSC –> Normal_Operation –> Tests –> Capacitance
3. The Capacitance Test screen is now displayed and the test data can be viewed (Fig. 80).
4. Close tth
he Capacitance Test display screen by clicking on the X in the upper right corner of the screen.

PTU Tool-
FIG. 79. PSC CAP
CAPACITANCE
ACITANCE TEST SCREEN
ASSESS SEQUENCE. E–44403.
145
FIG. 80. CAPACIT

CAPACITANCE
ANCE TEST SCREEN. E–44404.
146
11. PHASE MODULE AND GA

GATE
TE DRIVER TROUBLESHOOTING GUIDE
11.1.
1.1. IN
INTR
TROD
ODUC
UCTI
TION
ON
WARNING: Traction motor
motor leads and the DC link may have high voltage present from charged capacitors.
Remove power and discharge capacitors per standard instructions before troubleshooting the equip-
ment. Auxiliary DC link charged indicating lights are provided on the top of the control for visual indica-
tion. It is recommended that the auxiliary DC lin
link
k be measured by separate instrumentation as well before
proceeding with maintenance or troubleshootin
troubleshooting.g. Failure to do so may result in personnel
personnel injury or death.
death.
WARNING: When troubleshooting this truck, unless stated otherwise the truck engine should be shut
down and power removed from the
the DC link. At 400 RPM engine speed, the DC link is normally comman-
ded to be energized. DO NOT use the REST mode to remove power while troubleshooting any of the truck
circuits.
Phase module faults can be either related to the phase module itself or its associated gate driver. The fault text will
identify the phase module in question. For example, PM1A+ would refer to phase module (PM) in inverter #1 (1),
phase A (A), positive module (+).
11.2.
1.2. TES
TEST/I
T/INSP
NSPECT
ECTION
ION PRO
PROCED
CEDURE
URE
1. Check the w PTU

PTU PSC Real Time Data screen to determine if the inverter involved in the phase module fault
is active or not.
2. Run the
the Inverter
Inverter VI
VI Test
Test a
as
s follo
follows
ws to determine
determine iiff the fault occurs
occurs again
again::
a. Apply the Parking

Parking Brake (prop
(propulsion
ulsion syste
system
m commande
commanded
d to REST mode) and place th
the
e Direction Selec
Selector
tor
switch in the NEUTRAL position.
b. Start
Start a
and
nd run
run the
the eng
engine.
ine.
c. When the engine

engine has achieved its idle spee
speed,
d, release the Par
Parking
king Brake (pr
(propulsio
opulsion
n system exit
exits
s REST
mode).
d. Monitor
Monitor status
status mess
message
agess on th
the
e w PTU
PTU PSC Real Time Data screen, Inverters section. In the right side
of the Inverters section of the screen, Inverter VI Test State is shown. During the Inverter VI Test, the
status box should read Test. Upon completion, tthere
here should be the message Completed.
e. If no faults are logged, and there is no recent history of inver

inverter
ter faults, the truck can be released for service.
If faults are logged proceed with the remainder of this troubleshooting section.
3. Shut down ththe

e engine
engine but mmainta
aintain
in cont
control
rol power
power to the
the pro
propuls
pulsion
ion control
control.. Go to th
the
e phas
phase
e modu
module
le in que
questio
stion
n
as identified by the fault, and pull out its gray fiber optic connector.
connector. The red LED should be ON.
WARNING: When viewed under some conditions, the optical port may expose the eye beyond the maxi-
mum permissible exposure recommended in ANSI z136.2, 1993.
a. If the red LED
LED is ON, the
the IGBT o
on
n the phase
phase modu
module
le is not shorte
shorted.
d. Gate dr
drivers,
ivers, h
however
owever,, can iintermittently
ntermittently
fail, therefore, the LED indication does not guarantee that the gate driver is OK.
b. If the red LED is OFF,

OFF, that is usually an indication that
that the IGBT on the phase module
module is shorted or the gate
gate
driver has failed.
147
4. Ch
Chec
eck
k the
the gat
gate
e drive
drivers
rs as ffol
ollo
lows:
ws:
a. Disconnect
Discon nect the GDPC plug from the
the gate dr
driver
iver and c
check
heck for 9
90
0 to 100 V AC @ 25 Hz squa
square
re wave signal
signal at
the circular plug. (A Simpson analog meter is rrecommended
ecommended for this measurement.)
measurement.)
b. Verify that the input power to the GDPC is at least 50 volts at its input terminals.
c. If the AC output is less than 90 V AC, unp

unplug
lug all the ga
gate
te drivers on the inverter
inverter in quest
question.
ion. Then plug the
them
m
in one at a time, waiting about five seconds before reading the AC output voltage as each gate driver is
plugged in.
d. If the output
output falls be
below
low 90 V AC, replace tthat
hat gate dr
driver
iver..
e. Continue
Continue to check all
all the gate drivers
drivers for th
this
is 90 V AC thresho
threshold.
ld.
5. If the gate driver an

and
d the IGBT test OK, but the tru
truck
ck has a recent history o
off repeat
repeated
ed failur
failures,
es, repla
replace
ce the phase
module.
6. Inspec
Inspectt al
alll la
lamin
minate
ated
d bus
bus ba
bars
rs for damage
damage..
7. Use a volt–ohm
volt–ohm meter to check
check resistance
resistance tto
o groun
ground
d on tthe
he DC link circ
circuit.
uit. Using tha
thatt same meter
meter,, check
check for
short circuits on the DC link from the positive horizontal bus bar to the negative horizontal bus bar.
8. Inspec
Inspectt all oth
other
er phas
phase
e mod
module
ules
s fo
forr fla
flash
sh bu
burns
rns..
9. Check all
all phase module
module fuses
fuses fo
forr conti
continuity
nuity ((there
there a
are
re two fuses
fuses in pa
parallel
rallel pe
perr phase m
module)
odule)..
148
12. 17FB144 AND 17

17FB147
FB147 CIRCUIT CARD T
TROUBLESHOOTING
ROUBLESHOOTING GUIDE
12.1
12.1.. IN
INTR
TROD
ODUC
UCTI
TION
ON
Often, 17FB144 and 17FB147 boards used in 150 ton OHV propulsion systems have no defects found when re-
turned to the factory for unit exchange (UX) repair. It is believed that most of the perceived defects are the result of
problems communicating to the boards with the PTU, combined with a misunderstanding of the light patterns seen on
the bottom edge of the card. This section provides a definition of the light patterns on the card bottom edge and de-
scribes a procedure to use Microsoft HyperTerminal
HyperTerminal to troubleshoot 17FB144 and 17FB147 boards.
12.2
12.2.. CA
CARD
RD ED
EDGE
GE LIGH
LIGHTS
TS
There are two LED indicators on the bottom front edge of the boards defined as follows:
LED1 / WDTIME – Watchdog timer indicator.

ON – Watchdog Timer
Timer timed out.
OFF – Watchdog T
Timer
imer not timed out.
LED2 / FATL – Fail indicator.

ON – CPU reset or CPU fails its self test or EPROM checksum error.
OFF – No condition met for ON state.
The LED indicators flash during boot–up and can flash if no program is installed in the CPU board. LEDs can also
flash if the 5 V Power Supply is low. Normally, the CPU board is functional and can be communicated with, or down-
loaded to, if the LEDs are flashing.
NOTE: If using
using HyperTermin
HyperTerminal
al while LEDs are flashing, text will be continuously scrolling with a variable
time delay between messages.
The FATL
FATL indicator can be ON solid if the 5 V Power Supply is low or if there is a major failure of the board. Always
check the 5V Power Supply voltage if the FATL
FATL indicator is ON soli
solid.
d.
Typical LED patterns for Version 19 software are listed in TABLE 6.
12.3.
12.3. TRO
TROUBL
UBLESH
ESHOOT
OOTING
ING PRO
PROCED
CEDURE
URE
Figure 81 shows the troubleshooting flow chart for both 17FB144 and17FB147 boards.
The flow chart references other figures to provide details where necessary.
149
TABLE 6. TYPICAL 17FB144 AND 17FB147 BOARD LED P

PA
ATTERNS FOR
VERSION 19 SOFTWARE
BOARD OTHER
PRO- CPU
GRAMMED BOARD
(PROGRAM PRO-
BOARD PROB- IN FLASH GRAM–
CONDITION LEM MEMORY)? MED? 17FB144 BOARD 17FB147 BOARD
WDTIME LIGHT FATL WDTIME LIGHT FATL
LIGHT LIGHT
1 Running / Major failure xx xx xx ON solid xx ON solid
Power–up
2 Running / 5V power 1 sup- xx xx ON solid or 2 ON solid or 2 ON solid or 2
Power–up ply low flashing flashing flashing
3 Running None / Onboard Yes xxx OFF OFF OFF OFF
battery low 3
4 Running None / Onboard No Yes OFF or 4 OFF or 4 OFF or 4 OFF or 4
battery low 3 1. Flash twice 1. xxx 1. Flash twice 1. xxx
2. Flash 2. Flash 2. Flash 2. Flash
3. 1 sec. delay 3. xxx 3. 1 sec. delay 3. xxx
4. Flash 4. xxx 4. Flash 4. xxx
5. Repeat after 5. Repeat after 5. Repeat after 5. Repeat after
variable variable variable variable
time delay time delay time delay time delay
5 Running None / Onboard No No OFF OFF OFF OFF
battery low 3
6 Power–up None / Onboard Yes xx 1. Flash 1. Flash 1. Flash 1. Flash
battery low 3 2. 1 sec. delay 2. 1 sec. delay
3. Flash 3. Flash
4. 3 sec. delay
5. Flash twice
7 Power–up None / Onboard No xx 1. Flash 1. Flash 1. Flash 1. Flash
battery low 3 2. 1 sec. delay 2. 1 sec. delay
3. Flash 3. Flash
8 Power–up None but serial xx xx Flash once only, Flash once only, Flash once only, Flash once only,
with PTU com cable prob- then OFF then OFF then OFF then OFF
attached lem between
board and PTU
5
NOTE: Voltages listed are approximate.

1 –Measure voltage between TP4 – WDDIS and TP2 – GND on either the 17FB144 or 17FB147 board.
Reading should be at least 4.95 V.
2 –
Lights will be on solid for TP4 – WDDIS to TP2 – GND voltages below 4.9 V. Above 4.9 V to 4.95 V
V,, lights
may flash. Lights my also flash if the 5 V power supply voltage
voltage is oscillating.
3 – Low battery will not effect microprocessor board operation. However
However,, statistical data and other values stored
in RAM may be lost.
4 – Light pattern can vary per board as well
wel l as if the w PTU
PTU (PC) is connected to the relevant board serial port.
5 –Open w PTU
PTU serial communication ground wire with w PTU
PTU connected can cause board boot–up (buck)
routine to not run during power–up. https://www.besttruckmanuals.com/
150
See Sheet 2 of 2
FIG. 81. 17FB144 AND 17FB147 BOARD TROUBLESHOOTING PROCEDURE (SHEET 1 OF 2). E–44732.
151
See Sheet 1 of 2
FIG. 81. 17FB144 AND 17FB147 BOARD TROUBLESHOOTING PROCEDURE (SHEET 2 OF 2). E–44732.
152
12.4. USING HYPER

12.4. HYPERTERMI
TERMINAL
NAL T
TO
O COMMUN
COMMUNICA
ICATE
TE T
TO
O 17FB
17FB144
144 AN
AND
D
17FB147 BOARDS
HyperTerminal is a terminal emulator package that is included in Microsoft Windows 95/98 and 2000. This soft-
HyperTerminal
ware package can be used to communicate to either CPU board through
through the normal PTU connection. It allows access
to boot–up text that can be used to determine if communications with the CPU are active, the CPU board has passed
self tests, whether software
software has been loaded onto the board, if the software is running (and PTU communication prot
proto-
o-
col is active), and if any other abnormal situation exists.
The CPU board flash memory can also be erased using HyperTerminal.
HyperTerminal. This will subsequently allow PTU down-
loading of the software in cases where the CPU board is cycling messages and the PTU cannot break in and begin
downloading. HyperTerminal
HyperTerminal is used to break into the boot–up routine and then flash mem
memory
ory is erased.
12.4.1
12.4.1.. Pit
Pitfal
falls
ls/T
/Trap
raps
sWWhe
hen
nUUsin
sing
gHHyp
yperT
erTerm
ermina
inall
If having communications problems with the PTU, it is common to close the PTU window and try again. If the
window
windo w is closed while the PTU is trying to communicate, the COM1 port may not be released by the PTU and Hyper-
Terminal will not be able to connect to it. In this instance, HyperT
HyperTerminal
erminal will genera
generate
te a message Unable to Open
COM1 and the banner at the bottom left hand side of the main window will say Disconnected. Try to reset the COM1
port by disabling it and re–enabling it at the window shown in Figure 82. If this does not work, reboot the computer.
Should say this if com port is OK
FIG.82. COM1 SERIAL PORT WINDOW

MESSAGE FOR PROPER OPERATION.
E–44733.
NOTE: The banner at the bottom left hand corner of the main window will say “Connected” and record
connection time if the COM1 port is active.
153
HyperTerminal saves previous session text (without asking). If it is necessary to verify that the text stored in the
HyperTerminal
HyperTerminal
HyperTerminal window is from onl
onlyy the present session only
onl y, start a new connection.
The HyperTerminal
HyperTerminal screen shows a white background for text that is in the latest window. If the window is scrolled
backwards, the background turns light blue. The boarder between the white and light blue background in no way
indicates anything about the timing of the text displayed, just that the text contained within the present HyperTerminal
connection is more than one window long.
12.4
12.4.2
.2.. Ac
Acce
cess
ssin
ing
g Hyp
Hyper
erT
Termi
ermina
nall
Before beginning, connect the serial cable to the relevant CPU board serial port and to the COM1 port on the PC.
1. HyperT
HyperTer
ermi
mina
nall is loca
locate
ted
d unde
underr th
the
e Start Menu –> Program Files –> Accessories –> Communications –>
Hyper Terminal. Then double click on the Hypertrm.exe icon (see Figure 83).
NOTE: HyperTerminal can also be accessed from the wPTU  login window by selecting the Terminal
Emulator Mode radio button (Fig 4).
2. The window shown in Figure

Figure 84 wi
willll app
appear
ear an
and
d ask tto
o name tthe
he new c
connec
onnection
tion a
and
nd pick
pick an ico
icon.
n. If a co
connec
nnec--
tion
iconwas
frompreviously defined,
those provided, andjust clickOK
click Cancel
. . If defining a new connection, type in the new name, select an
3. The Connect To window shown in Figure 85 will appear

appear.. Select Direct to Com1 in the Connect using menu
selection and then click OK.
4. The COM1 Properties window shown in Figure 86 will appear.

appear. Select the followi
following
ng and then click OK. (Ad-
vanced settings do not need to be adjusted):
Bits per second = 9600 (Default = 2400)
Data bits = 8 (Default)
Parity = None (Default)
Stop bits = 1 (Default)
Flow control = None (Default = Hardware)
Double click here
FIG. 83. HYPERTERMINAL ICON. E–44734.
154
FIG. 84. HYPERTERMINAL NEW

CONNECTION WINDOW. E–44735.
FIG. 85. HYPERTERMINAL CONNECT TO

WINDOW. E–44736
155
FIG. 86. HYPERTERMINAL COM1

PROPERTIES WINDOW. E–44737
5. After the
the COM1 proproperti
perties
es are set, tthe
he main Hyp
HyperT
erTermin
erminal
al window will
will look like that
that shown in Figure
Figure 87, iiff
HyperTerminal
HyperT erminal is able to connect to the COM1 port.
NOTE: The lower left hand banner will say “Connected” and count the connection time. This only indi-
cates that HyperTerminal has access to the COM1 port, NOT that HyperTerminal can talk to the connected
CPU board.
6. If HyperT
HyperTerminal
erminal cannot
cannot con
connect
nect tto
o COM1
COM1,, a me
message
ssage window appea
appears rs tha
thatt say
says
s Unable to Open COM1 an and
d
the banner will say Disconnected as shown in Figure 88. If this happens, try to reset the COM1 port by disab-
ling it and re–enabling it at the window previously shown in Figure 82. If this does not work, reboot the computer.
7. Once HyperT
HyperTermin
erminal
al is connecte
connected
d to the COM1
COM1 port, cycle cocontro
ntroll power tto
o the con
connecte
nected
d CPU boar
board.
d. The
screen will appear as shown in Figure 89 if the CPU board is already programmed and running. running. Only the
17FB144 board will show the text line pertaining to the battery test. Figure 89 shows the HyperT
HyperTerminal
erminal main
window scrolled backwards 1 line to show the complete text that comes out of the CPU board.
NOTE: The HyperTerminal screen shows a white background for text that is in the latest window. If the
window is scrolled backwards, the background
background turns lig
light
ht blue. The boarder between
between the white and light
blue background in no way indicates anything about the timing of the text displayed, just that the text
contained within the present HyperTerminal connection is more than one window long.
8. The screen will

will appear
appear as shown in Figure 90 if the CPU board is not programmed.
programmed. Only th
the
e 17FB14
17FB144
4 boar
board
d will
show the text line pertaining to the battery test.
NOTE: Unit Exchange (UX) cards are not programmed when shipped.
NOTE: The following text message will scroll with a variable time delay between cycles if the LED lights
on the bottom edge of the CPU board are flashing. Lights may or may not flash if no program is installed
in the CPU board.
156
9. To erase the flas

flash
h memory
memory (pro
(program)
gram) on a C
CPU
PU board, the boo
boot–up
t–up ro
routine
utine must
must be interrupt
interrupted.
ed. To do this, h
hold
old
down the TAB key and cycle control
control power to the board. Let the TAB key up when you see the Keyboard
interrupt accepted message as shown in Figure 91.
10. After the boot–up routine

routine has been inter
interrupted
rupted,, the CPU board flash me
memory
mory (pr
(program
ogram)) can be erased by typ-
ing ef and hitting ENTER. When typing in the ef characters, they will most likely appear somewhere to the far
right of the =>. This is OK, just type them in and hit ENTER. The message shown in Figure 92 should appeappear
ar if
the flash memory was erased successfully.
11. An open PTU serial

serial communication
communication ground wire with the PTU connected can cause the CPU board boot–up
(buck) routine to not run during power–u
power–up.
p. If this happens, tthe
he text in HyperT
HyperTerminal
erminal will stop after the 25MHZ
board detected message as shown in Figure 93.
12. When exiting HyperTermin

HyperTerminal,
al, it will as
ask
k you if you want
want to save tthe
he sess
session.ion. If you c
click
lick OK, you can select the
session name the next time you enter HyperT
HyperTerminal
erminal and you wi willll not have to perform the communications
set–up.
NOTE: If you do save the session, any text that was in the HyperTerminal window
wi ndow (including
(incl uding that
tha t scrolled
scroll ed
past the view window) will also be saved.
After the initial save, HyperTerminal

HyperTerminal saves session text (without asking) every time you close it. If it is n
necessar
ecessary
y to
verify that the text stored in the HyperT
HyperTerminal
erminal window is from the present session only, start a new connection.
Banner shows “Connected”

and counts connection time
FIG. 87. HYPERTERMINAL MAIN WINDOW WHEN CONNECTED TO COM1 PORT.
PORT. E–44738
157
Message window
Banner shows “Disconnected”
FIG. 88. HYPERTERMINAL MAIN WINDOW WHEN NOT CONNECTED TO COM1 PORT.
PORT. E–44739
158
Light blue screen

only because screen
scrolled back one line
This line only

17FB144 seen
board for
(TCI).
Program is installed and running.

CPU board has switched to PTU
protocol.
FIG. 89. HYPERTERMINAL MAIN WINDOW AFTER CYCLING CONTROL POWER, PROGRAM
INSTALLED AND RUNNING. E–44740.
159
Scroll up to see the beginning

of text message.
Program NOT installed.
This line only seen for 17FB144 board (TCI).
Program NOT installed.
Program NOT running.
FIG. 90. HYPERTERMINAL MAIN WINDOW AFTER CYCLING CONTROL POWER, PROGRAM NOT
INSTALLED. E–44741
160
Hold TAB key down until

this message appears
while cycling power.
FIG. 91. HYPERTERMINAL MAIN WINDOW AFTER CYCLING CONTROL POWER, WITH TAB
TAB KEY
HELD DOWN (INTERRUPTING BOOT–UP ROUTINE). E–44742.
161
Type in “ef” and hit Enter.

Characters may show up to
the far right of the =>.
Flash memory successfully erased
FIG. 92. HYPERTERMINAL MAIN WINDOW AFTER ERASING CPU BOARD

FLASH MEMORY. E–44743
E–447 43
162
FIG. 93. HYPERTERMINAL MAIN W

WINDOW
INDOW WHEN BOOT–UP (BUCK ROUTINE) DOES NOT RUN
DUE TO OPEN PTU SERIAL CABLE GROUND WIRE WITH THE PTU CONNECTED. E–44744.
163
164
13. GLOSSARY OF TERMS

Listed in TABLE 7 are terms used within this document and abbreviations as shown on the system schematic.
NOTE: Those components

components marked with an asterisk (*) may no
nott be present in all control groups.
groups. Refer to
truck specific schematic for configuration details.
TABLE 7. GLOSSARY
Term Description
AFSE Alternator Field Static Exciter (17FM689) panel regulates the current in the alternator field.
AFSER Alternator Field Static Exciter Resistor
Resistor facilitates battery boost
boost to AFSE. AFSER is used
in the low side driver circuit.
ALT
ALT Alternator (5GTA22) is a salient-pole, three-phase, Y-connected, AC machine that is
mounted solidly to the diesel engine and is driven by the engine crankshaft. The alternator
provides electrical power for propulsion and control systems.
AMBTS Ambient Temperature
Temperature Sensor, located in the air inlet to the inverters, senses ambient air
temperature.
ANALOG I/O CARD PSC Analog Input/Output Card (17FB173) provides signal conditioning for analog signals
(PSC) to/from the Propulsion System Control Panel. This card monitors system voltages and cur-
rents along with frequency tachometer inputs from the hydraulic blower system and the
engine. It also contains the digital alternator field control system
system..
ANALOG I/O CARD TCI Analog Input/Output Card (17FB160) provides signal conditioning for analog signals
(TCI) to/from the Truck Control Interface Panel. This card monitors signals from sensors located
throughout the truck and provides driving signals for operator cab meters.
BAROP Barometric Pressure Sensor provides a barometric pressure signal to the control system
used in the calculations of control system cooling requirements.
BATFU Battery Power Fuse provides overload protection to the control equipment.
BATTSW OEM supplied Battery Switch is used to connect/disconnect battery voltage from the truck
control equipment.
BD1 Battery Blocking Diode provides isolation between the Battery Line Filter output voltage
and truck battery voltage.
BFC Battery Filter Capacitor

tronics panels Assembly
in the presence is used voltage
of battery to temporarily sustain
dips and control power to the elec-
outages.
BFCR* Battery Filter Capacitor Resistor is used to limit inrush current to the Battery Filter Capaci-
tor. NOTE: Used only in the 17KG527B1 Control Group configuration.
BLFP* Battery Line Filter Panel (17FM311) reduces voltage ripples in the control power lines from
the battery to provide “smooth” power for the Propulsion Control Panel and Truck Control
Interface. NOTE: Not used in 17KG527B1 configuration, since the 17FH41 Power
Supply contains its own input filtering.
BM1 Blower Motor #1 (5GY19) is a DC motor located within the Retarding Grid assembly. The
motor drives two blowers (fans). The blowers provide cooling air for the Retarding Resis-
tors in the Retarding Grid assembly during dynamic retarding operations and self–load
testing.
BM1I Grid Blower Motor #1 Current Measuring Module used to measure the DC current flow
through the grid blower motor.
CCF1,
CIF21, CIF11,
CIF22 CIF12, Inverter #1 Filter
instantaneous Capacitors
power when thestore and filter
Inverter1 the Inverter
GTO/IGBT Phase#1Modules
DC bus first
voltage
turn to
on.provide
CCL1, CCL2 Capaci tor Charge Indicating Lights #1 and #2 are illuminated when 50 volts or more is pres-
Capacitor
ent on the DC link (the DC bus that connects the Alternator output, Chopper Module/Resis-
tor Grid circuits, and traction Inverters).
165
TABLE 7. GLOSSARY (Cont’d)

Term Description
CCLR1, CCLR2 Capacitor Charge Resistor Panels #1 and #2 are connected across the DC link to provide
a voltage attenuated sample of the DC link voltage to the Capacitor Charge Indicating
Lights.
CD1, CD2 Chopper Diode #1, #2 same as positive IGBT module.
CF Chopper Fuses same as inverter phase fuses.
CGBM1, CGBM2* Blower Motor di/dt Reduction Capacitors are used to limit the rate of current change in the
retard grid blower motor circuit. NOTE: Used only in the 17KG527
17KG527B1 B1 Control Group
configuration.
CMAF Alternator Field Current Sensor detects the amount of current flow through the Alternator
field winding.
CMT Alternator Tertiary Current Sensing Module detects the amount of AFSE current supplied
by the Alternator tertiary winding.
CM1, CM2 IGBT Chopper Modules #1 and #2 (17FM797) control the DC voltage applied to the grid
resistors during retarding operations same as negative inverter phase module.
CM1A, CM1B Phase 1A and 1B Current Sensing Modules detect the amount of current flow through the
A and B phases of Traction Motor #1.
CM2A, CM2B Phase 2A and 2B Current Sensing Modules detect the amount of current flow through the
A and B phases of Traction Motor #2.
CPR Control Power Relay (17L
(17LV66)
V66) is picked up when the Key Switch and Control Power Switch
are closed. CPR contacts are used to conn
connect/disconnect
ect/disconnect batt
battery
ery voltage to the propulsion
system.
CPRD Control Power Blocking Diode provides diode blocking between the control power switch
input and the control power digital output.
CPRS CPR Suppression Module limits the transient voltage induced into the battery system
whenever power to the CPR coil is interrupted.
CPS Control Power Switch (mounted on the diagnostic panel) is used to connect/disconnect
battery voltage to/from the control system.
CPU CARD (PSC) System CPU Card (17FB147) in the ICP provides control system processing
processing and serial link
communication.
CPU CARD (TCI) System CPU Card (17FB144) in the ICP provides the processing of truck systems I/O and
serial link communication.
CVB Laminated bus bar for IGBT inverter and chopper.
DID Diagnostic Information Display (17FM558) provides operator/maintenance personnel with
the ability to monitor the operational status of certain truck systems and perform system
diagnostic tests.
DIGITAL I/O CARD System Digital Input/Output Card (17FB104) provides battery–level drive signals to control
(PSC) relays, contactors and LEDs; and receives battery–level status feedbacks of relays, con-
tactors and switches.
DIGITAL I/O CARD System Digital Input/Output Card (17FB104) provides battery–level drive signals to control
(TCI) https://www.besttruckmanuals.com/
relays, contactors and lights; and receives battery–level status feedbacks of relays, con-
tactors and switches.
ESS Engine Speed Sensor that is mounted on the alternator, which is directly coupled to the
engine.
EWMS Engine Winter Mode Switch allows Detroit Diesel engines to run in Heat Keeping mode
when the engine controller commands it and the switch is in the Winter position.
166

Term Description
FB1L, FB2L Filter Capacitor Bus Bar which connects the left–side filter capacitor to vertical laminated
bus bar.
FB1R, FB2R, FBCL Filter Capacitor Bus Bar which connects the right–side filter capacitors to vertical laminated
bus bar.
FDR* Filter Discharge Resistor Panel is a resistor divider connected across the DC link. FDR
discharges the DC link.
FIBER OPTIC AS- Fiber Optic Assembly provides voltage and noise isolation for the control and feedback sig-
SEMBLY nals between the Propulsion Control Panel and the Phase/Chopper Modules.
FP Filter Panel (17FM460) is connected across the three–phase output of the Alternator to
filter electrical noise.
GDPC Gate Drive Power Converter provides gate drive power for IGBT phase and chopper mod-
ules. GDPC contains both GDPC1 and GDPC2.
GF Generator (Alternator) Field Contactor (17CM55) connects the AFSE to the Alternator
field. GF is controlled by the Propulsion Control Panel.
GFCO GF contactor cut–out switch provides a means of mechanically preventing energization of
the GF contactor, thereby providing a means to ensure that the DC link is not energized.
GFM Gate Firing Module (17FM415) receives the incoming pulses from the Analog Input/Output
Card in the Propulsion Control Panel, converts them into appropriate AFSE control signals.
GFR Generator Field Relay (17LV66) picks up with the GF contactor and is used for alternator
field control.
GFRS GFR Suppression Module limits the transient voltage induced into the battery system
whenever power to the GFR coil is interrupted.
GFS GF Suppression Module limits the transient voltage induced into the battery system when-
ever power to the GF coil is interrupted.
GRR Ground Resistor Panel is a voltage divider connected across the DC link, used with GRR9
and GRR10 to detect system ground faults.
GRR9 GRR9 is used in conjunction with GRR and GRR10 to measure ground fault current.
GRR10 GRR10 is used in conjunction with GRR and GRR9 to measure ground fault current.
I1VB, I2VB Laminated vertical bus bar for IGBT inverter and chopper.
ICP Control electronics panel (17FL375) containing all functions formerly provided by the sepa-
rate PSC and TCI panels.
INV1 TMC CARD Inverter #1 Traction Motor Control (TMC) Card (17FB172) combines the functions pre-
viously provided in the CPU (17FB138) and I/O (17FB134) cards into a single inverter con-
trol card.
INV2 TMC CARD Inverter #2 Traction Motor Control (TMC) Card (17FB172) combines the functions pre-
viously
viousl y provided in the CPU (17FB138) and I/O (17FB134) cards into a single Inverter Con-
trol Card.
I1CO* Inverter #1 Cut Out Switch (located in the Operator Interface
Interface area of the Main Control Cabi-
net), whenhttps://www.besttruckmanuals.com/
closed, is used to cut out Inverter #1. NOTE: Not used on B1 or later configu-
rations.
I2CO* Inverter #2 Cut Out Switch (located in the Operator Interface area of the Main Control Cabi-
net), when closed, is used to cut out Inverter #2. NOTE: Not used on B1 or later configu-
rations.
KEYSW OEM supplied Keyswitch is used to connect/disconnect battery voltage to/from CPR.
167

Term Description
LEDP* Light–Emitting Diode Panel (located in the Operator Interface area of the Main Control
Cabinet) provides a visual indication of system status:
CPR is illuminated when CPR is picked up
SYS
SYS RU
RUN
N is ill
illum
umin
inat
ated
ed w
whe
hen
n IICP
CP ((or
or PS
PSC,
C, as equ
equip
ippe
ped)
d) is o
ope
pera
rati
tion
onal
al
NAFL
NAFLT
T is il
illu
lumi
mina
natted when
when a res
estr
tric
icti
tive
ve ev
even
entt co
cond
ndit
itio
ion
n is pres
presen
entt
TEST is illuminated when the system is in the Test state
REST
REST is il
illu
lum
minat
inated
ed wh
when
en the syst
syste
em is in the Rest
Rest stat
state
e with
with powe
powerr rem
remov
oved
ed
from the DC link
LINKI Link Current Sensing Module detects the amount of current flow through the DC link (the
DC bus that connects the Alternator output, Chopper Module/Resistor Grid circuits, and
traction Inverters).
PF1A, PF1B, PF1C Inverter phase fuses, mounted on laminated bus bars, provide short circuit protection for
PF2A, PF2B, PF2C inverter phases to limit damage from IGBT failures.
PM1A+, PM1B+, Phase Modules (IGBT,
(IGBT, 17FM796) provide the positive driving voltages for each of the three
PM1C+ windings of Traction Motor #1.
PM1A–, PM1B–, Phase Modules (IGBT, 17FM797) provide the negative driving voltages for each of the
PM1C– three windings of Traction Motor #1.
PM2A+, PM2B+, Phase Modules (IGBT,
(IGBT, 17FM796) provide the positive driving voltages for each of the three
PM2C+ windings of Traction Motor #2.
PM2A–, PM2B–, Phase Modules (IGBT, 17FM797) provide the negative driving voltages for each of the
PM2C– three windings of Traction Motor #2.
PS Power Supply (17FH41) which provides +5VDC, ±15VDC, ±24VDC regulated voltage.
PSC Propulsion System Controller, is one of the CPU cards (17FB147) in the ICP panel.
RD Rectifier Diode Panel (17FM528), also denoted as the main rectifier panel, converts the
output three–phase, AC voltage from the Alternator to DC voltage to power the two Invert-
ers.
RG1A, RG1B, RG1C, Grid Resistors dissipate power from the DC link during retarding, self–load, and Inverter
RG2A, RG2B, RG2C, Filter Capacitor discharge operations.
RG3A, RG3B, RG3C,
RGBM* Discharge Resistors for Blower Motor di/dt Reduction Capacitors are discharge resistors
for capacitors used to limit the rate of current change in the retard grid blower motor circuit.
NOTE: Used only in the 17KG527B1 Control Group configuration.
RP1 Retard Contactor,
Contactor, when closed, connects the Grid Resistors to the DC link during retard-
ing, self–load, and Inverter Filter Capacitor discharge operations.
RP1S RP1 Suppression Module limits the transient voltage induced into the battery system
whenever power to the RP1 coil is interrupted.
R1 Battery Boost https://www.besttruckmanuals.com/
Resistor limits surge current in the Alternator field circuit when the GFR con-
tacts initially close.
SS1, SS2 Traction Motor Speed Sensors which provide Traction Motor speed signals to the respec-
tive Inverter control cards.
SS3, SS4 Front Wheel Speed Sensors. Front Wheel Speeds are monitored for wheel slips/slide con-
trol logic.
168

Term Description
TCI Truck Control Interface, is one of the CPU cards (17FB144) in the ICP panel.
TH1 Alternator Field Thyrite (Varistor) protects the Alternator field circuit from voltage tran-
sients.
TM1, TM2 Motorize d Wheels 1 and 2 each consisting of a Traction Motor and a T
Motorized Transmission
ransmission Assem-
bly. The three–phase asynchronous Traction Motors convert electrical energy into me-
chanical
chanic al energy. This mechan
mechanical
ical energy is transmitted to the wheel hub through the speed
reducing Transmission Assembly
Assembly..
VAM1, VAM2 Voltage Attenuation
Attenuation Modules #1 and #2 (17FM702) are eight–channel devices for the in-
verters. VAM1 and V VAM2
AM2 are used to attenuate high voltage motor to line neutral and DC
link values to a level acceptable to the control electronics.
VAM3, VAM4 Voltage Attenuation Modules #3 and #4 (17FM681) are five–channel devices for system
use. VAM3 and VAM4VAM4 are used to attenuate high voltages to a level acceptable to the con-
trol electronics.
169
170
14. SOFTWARE VERSIONS
14.1.
14.1. VER
VERSIO
SION
N119,
9, JUL
JULY
Y 20
2002
02
Version 19 was developed to support end–user and OEM requests as well as addressing reliability improvements
and product enhancements to the GE propulsion system.
Version 19 software is for the 17FL320 Propulsion System Controller panel, the 17FL349/17FL373 Truck Control
Interface panel, or the 17FL375 Integrated Control Panel, and a portable PC. It may be applied to all GETS OHV AC
propulsion systems, including the 17KG498xx, 17KG526Bx and 17KG527xx groups.
Version 19 includes all application software for the control system panels as well as the MS–Windows based PTU
(w PTU
PTU) listed in TABLE 8.
NOTE: The FB173 card software is downloaded

downloaded automatically at startup by the system.
General informatio
informationn for version 19 and previous versions of software is listed in TABLE 9. Refer to the SMI# shown
in the table for specific information.
TABLE 8. VERSION 19 SOFTWARE

Software Name Version Location
Controller Software
Propulsion System Controller (PSC) 19.03a 17FL320 or 375
Truck Control Interface (TCI) 19.03a 17FL349, 373, or 375
Inverter – IMC Version (17FB138/17FB134) 02.19.03 17FL320
Inverter – TMC Version (17FB172) 05.19.03 17FL320 or 375
Windows PTU and toolbox (Release 1.0)
AC PTU 19.03 PC
AC Mine and OEM Configuration Utility 19.03 PC
OHV Download Utility 2.0 PC
OHV Datalogger Utility X16, July 2001 PC
OHV Datalogger Graphing Utility B6.4 PC
FB173 Card Software (17FL375 Panel Only)
17FB
17FB17
173
3 Card
Card – CP
CPLD
LD Vers
ersion
ion (17
17KG
KG52
526,
6, 527
527 On
Only
ly)) 3 or Hi
High
gher
er 17FB
17FB17
173
3 Ca
Card
rd
Software Name Version Location
17FB173 Micro–Controller
Micro–Controller Software (17KG526, 527 2.42 17FB173 Card
Only)
17FB173 Alternator Field Programmable Gate Array 3.2, 01
01/28/01 17FB173 Card
(FPGA) (17KG526, 527 Only)
17FB173 Speed FPGA (17KG526, 527 Only) 7.3, 09/26/00 17FB173 Card
171
14.2.
14.2. VER
VERSIO
SIONS
NS INF
INFORM
ORMA
ATION
TION
TABLE 9. SOFTWARE VERSIONS INFORMATION

Version Date Released GETS SMI # Status Notes
19 July 2002 41A322501BD Active Current version for all propulsion
system models; includes support for
w PTU
PTU
18 May 2001 41A322501BC Obsolete Added support for KG526 and
KG527 groups
17 August 1999 41A322501BB Obsolete General improvements
16 October 1998 41A322501BA Obsolete General improvements
14 June 1998 N/A Obsolete Added support for high altitude op-
eration
13 October 1997 N/A Obsolete Added support for Tar Sands opera-
tion
12 September 1997 N/A Obsolete First official version for KG498

groups
172


Terex 150 Ton ACOHV Propulsion Systems Fault Codes DTC

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Copyright 2003 General Electric Company.

These instructions do not purport to cover all details or variations in equipment

THERE ARE NO WARRANTIES OF ACCURACY, MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE.

VTI For 150 Ton AC OHV Propulsion Systems, GET–6869

2. PORTABLE TEST UNIT (PTU) DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3. SELECTED SCREEN DESCRIPTIONS AND FUNCTIONS . . . . . . . . . . . . . . . . . . . . . 11

4.3. GE/OEM Default Configuration Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

GET–6869, VTI For 150 Ton AC OHV Propulsion Systems

5. INSTALLING AC PROPULSION SYSTEM SOFTWARE ON TRUCK . . . . . . . . . . . 33

6. TRUCK START–UP PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

6.19.3. Self Load Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

VTI For 150 Ton AC OHV Propulsion Systems, GET–6869

8. DIAGNOSTIC INFORMATION DISPLAY (DID) PANEL . . . . . . . . . . . . . . . . . . . . . . 115

8.3.3. Link Capacitance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

9. EVENT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

10. SPECIAL OPERATIONS AND TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

11. PHASE MODUL

GET–6869, VTI For 150 Ton AC OHV Propulsion Systems

13. GLOSSARY OF TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

14. SOFTWARE VERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Table. No. Description Page

VTI For 150 Ton AC OHV Propulsion Systems, GET–6869

Fig. No. Description Page

GET–6869, VTI For 150 Ton AC OHV Propulsion Systems

LIST OF ILLUSTRATIONS (Cont’d)

Fig. No. Description Page

84. HYPERTERMINAL NEW CONNECTION WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

VTI For 150 Ton AC OHV Propulsion Systems, GET–6869

LIST OF ILLUSTRATIONS (Cont’d)

Fig. No. Description Page

GET–6869, VTI For 150 Ton AC OHV Propulsion Systems

VTI For 150 Ton AC OHV Propulsion Systems, GET–6869

Information on the screen content and functions of the w PTU

NOTE: If a need arises

GET–6869, VTI For 150 Ton AC OHV Propulsion Systems

VTI For 150 Ton AC OHV Propulsion Systems, GET–6869

2. PORTABLE TEST UNIT (PTU) DESCRIP

NOTE: Refer to GEK–91712, OHV wPTU  User’s Guide, for complete

2.2. OHV w PTU

GET–6869, VTI For 150 Ton AC OHV Propulsion Systems

2.2.4. Setting Pro

VTI For 150 Ton AC OHV Propulsion Systems, GET–6869

Login Screen (FIG. 4)

When the LOGIN to w PTU

The set of screens dedicated to TCI interaction

The set of screens dedicated to PSC interaction and operation

NOTE: A brief description

GET–6869, VTI For 150 Ton AC OHV Propulsion Systems

FIG. 2. TCI WINDOW BROWSER SCREEN SELECTIONS. E–44410B.

VTI For 150 Ton AC OHV Propulsion Systems, GET–6869

FIG. 3. PSC WINDOW

GET–6869, VTI For 150 Ton AC OHV Propulsion Systems

NOTE: Refer to GEK–91712, OHV wPTU  User’s Guide, for complete

VTI For 150 Ton AC OHV Propulsion Systems, GET–6869

Datalogger and Graph Data functions are contained in the GE OHV w PTU

A saved screen can be replayed in both online and offline

NOTE: On some PTUs,

GET–6869, VTI For 150 Ton AC OHV Propulsion Systems

VTI For 150 Ton AC OHV Propulsion Systems, GET–6869

3. SELECTED SCREEN DESCRIPTIONS AND FUNCTIONS