Manual Fallas Terex

GET6869
VEHICLE TEST, DIAGNOSTIC, AND wPTUt INSTRUCTIONS FOR 150 TON AC OHV PROPULSION SYSTEMS
ECopyright 2003 General Electric Company. All rights reserved. This copyrighted document may be reproduced free of charge by General Electric Company customers (OEMs) 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 nor to provide for every possible contingency to be met in connection with installation, operation, or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the users 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.
VTI For 150 Ton AC OHV Propulsion Systems, GET6869
CONTENTS
Page
1. OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1. 1.2. TOOLS AND TEST EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 HANDLING ELECTRONIC PANEL PRINTED CIRCUIT CARDS . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. PORTABLE TEST UNIT (PTU) DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

wPTUt ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OHV wPTUt TOOLBOX OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1 .RealTime Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.2. Stored Event Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.3 .Statistical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.4. Setting Propulsion System Configuration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.5. Software Downloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.6. Data Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.7. System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.8. SelfTest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.9. Integrated Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.10. OneStep Downloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3. wPTUt SCREEN SELECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4. wPTUt STARTUP SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5. View Datalogger and Data Graph Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6. SAVING SCREEN DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7. PASSWORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1. 2.2. 3 3 3 3 3 4 4 4 4 4 4 4 4 8 9 9 9
3. SELECTED SCREEN DESCRIPTIONS AND FUNCTIONS . . . . . . . . . . . . . . . . . . . . . 11

Product Service Data Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Truck Specific Data Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . View Overspeeds Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Set Wheel Motor Types Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MONITOR REAL TIME DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.1. PSC Real Time Data Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.2. PSC Serial Link Data Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.3. PSC Analog Inputs Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.4. PSC Temperatures Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6. CHECK PSC MODE LOGIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.1. Accessing PSC Logic Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7. CHECK TCI ACCEL INHIBIT LOGIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.1. Accessing TCI Accel Inhibit Logic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8. CONSOLIDATED TRUCK DATA SAVE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1. 3.2. 3.3. 3.4. 3.5. 11 11 12 13 13 13 14 14 14 17 17 20 20 22
4. CONFIGURATION FILES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1. 4.2. 4.3. 4.4. 4.5. GE Configuration File Name Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . View Truck Configuration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GE/OEM Default Configuration Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GE/OEM Configuration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Saving New Configuration Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 25 27 29 31 i
GET6869, VTI For 150 Ton AC OHV Propulsion Systems
CONTENTS (Contd)
Page 4.6. 4.7. Configuration File Destination Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Configuration File Source Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5. INSTALLING AC PROPULSION SYSTEM SOFTWARE ON TRUCK . . . . . . . . . . . 33

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

CIRCUIT CONTINUITY AND RESISTANCE CHECKS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.1. VOM Circuit and Component Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2. MEGGER TEST FOR GROUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.1. Preparation For Megger Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.2. Megger Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.3. Restore Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3. TROUBLESHOOTING FOR GROUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4. LOW VOLTAGE POWER SUPPLY CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.1. Preparation for Power Supply Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.2. Power Supply Voltage Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5. PSC AND TCI CARD CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6. LOAD AC OHV PROPULSION SYSTEM SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7. REST MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8. PSC MANUAL DIGITAL INPUT/OUTPUT TEST PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . 6.9. PEDAL, POT, AND LEVER ADJUSTMENT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10. GAUGE CALIBRATION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11. CONFIGURATION CHANGES DUE TO CALIBRATION CHECKS . . . . . . . . . . . . . . . . . . . . . . . 6.12. SET TIME AND DATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13. CHECK COMMUNICATION STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14. TCI ANALOG INPUT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15. TCI MANUAL DIGITAL OUTPUT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16. TCI MANUAL DIGITAL INPUT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17. DIAGNOSTIC INFORMATION DISPLAY (DID) PANEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18. INVERTER CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18.1. Inverter Phase Module Command and Feedback Circuitry Checks . . . . . . . . . . . . . . . . . . 6.19. SELF LOAD TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19.1. Preparation for Self Load Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19.2. Checks Prior to Self Load Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19.3. Self Load Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20. INVERTER LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21. FUNCTIONAL GROUND FAULT DETECTION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii 6.1. 47 47 48 48 49 49 50 51 51 51 51 52 52 52 56 61 61 63 65 67 67 69 70 70 70 73 73 73 74 76 78
CONTENTS (Contd)
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7. STATISTICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.1. 7.2. 7.3. 7.4. 7.5. 7.6. 7.7. GENERAL DESCRIPTION AND DEFINITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 VIEW STATISTICAL COUNTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 VIEW STATISTICAL PROFILES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 VIEW TRUCK STAT SERIAL REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 RESET STATISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 UPLOAD STATISTICAL DATA TO A FILE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 PROFILE (HISTOGRAM) DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
8. DIAGNOSTIC INFORMATION DISPLAY (DID) PANEL . . . . . . . . . . . . . . . . . . . . . . 115

8.1. 8.2. 8.3. MODES DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAULTS DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TEST DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.1. Self Load Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.2. Software Version Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.3. Link Capacitance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.4. Overspeed Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 117 118 119 120 120 121
9. EVENT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

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

10.1. 10.2. 10.3. 10.4. 10.5. WELDING ON THE TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOVING TRUCK WITH ONE WHEEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VOLTAGE ATTENUATION MODULE (VAM) CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current Measuring Module Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LINK CAPACITANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 143 144 144 145
11. PHASE MODULE AND GATE DRIVER TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

11.1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 11.2. TEST/INSPECTION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
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CONTENTS (Contd)
Page
12. 17FB144 AND 17FB147 CIRCUIT CARD TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

12.1. 12.2. 12.3. 12.4. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARD EDGE LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . USING HYPERTERMINAL TO COMMUNICATE TO 17FB144 AND 17FB147 BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4.1. Pitfalls/Traps When Using HyperTerminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4.2. Accessing HyperTerminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 149 149 153 153 154
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. DEFAULT CONFIGURATION FILES AND DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 2. GE/OEM CONFIGURATION OPTIONS AND DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 3. STATISTICAL DATA CODES COUNTERS 4. STATISTICAL DATA CODES PROFILES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5. EVENT CODE DESCRIPTIONS AND INFORMATION 7. GLOSSARY
6. TYPICAL 17FB144 AND 17FB147 BOARD LED PATTERNS FOR VERSION 19 SOFTWARE . . . 150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 8. VERSION 19 SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 9. SOFTWARE VERSIONS INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
iv
LIST OF ILLUSTRATIONS
Fig. 1. 2. 3. 4. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. No. Description Page wPTUt STARTUP SCREEN SELECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TCI WINDOW BROWSER SCREEN SELECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 PSC WINDOW BROWSER SCREEN SELECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 wPTUt TOOLBOX STARTUP SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 PSC SERIAL LINK DATA SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 PSC TEMPERATURES SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 PSC LOGIC SCREENS ACCESS SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 PSC READY MODE LOGIC SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 PSC PROPEL MODE LOGIC SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 PSC RETARD MODE LOGIC SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 TCI ACCEL INHIBIT LOGIC SCREEN ACCESS SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 TCI ACCEL INHIBIT LOGIC SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 CONSOLIDATED TRUCK DATA SAVE SELECTION FROM TOOLBAR. . . . . . . . . . . . . . . . . . . . . . . . . . . 22 CONSOLIDATED TRUCK DATA SAVE SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 COMPOSITION OF A GE AC OHV CONFIGURATION FILE NAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 TYPICAL TRUCK CONFIGURATION SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 OEM TRUCK CONFIGURATION FILE TREE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 OPEN AC CONFIGURATION TOOL SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 VIEW CONFIGURATION FILES SCREEN EXAMPLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 PTU SCREENS CONFIGURATION BROWSER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 SET GE / OEM OPTIONS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 SET WHEEL MOTOR TYPES SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 GE PRODUCT SERVICE DATA SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 TRUCK SPECIFIC DATA SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 OVERSPEEDS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 OHV PTU PROGRAMMING UTILITY SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 PROGRAMMING THE PANEL STATUS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 TCI SW VERSIONS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 TCI SET TIME AND DATE SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 RESET AND ERASE TCI EVENTS SELECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 TCI RESET STATS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 PSC SOFTWARE VERSIONS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 PTU BROWSER PSC MANUAL TEST SCREEN ACCESS SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . 53 PSC MANUAL TEST SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 PTU BROWSER TCI REAL TIME MENU ACCESS SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 TCI ANALOG INPUTS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 PTU BROWSER PSC REAL TIME MENU ACCESS SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 PSC ANALOG INPUT CHANNELS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 PSC REAL TIME DATA SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 PTU BROWSER TCI GAUGE CALIBRATION SCREEN ACCESS SEQUENCE. . . . . . . . . . . . . . . . . . . . 61 TCI GAUGE CALIBRATION SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 PTU BROWSER SET TIME AND DATE SCREEN ACCESS SEQUENCES. . . . . . . . . . . . . . . . . . . . . . . 63 SET TIME AND DATE SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 BROWSER TCI REAL TIME DATA SCREEN ACCESS SEQUENCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 v
LIST OF ILLUSTRATIONS (Contd)

Fig. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81. 71. 82. 83. 84. 85. 86. vi No. Description Page TCI REAL TIME SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 TCI MANUAL TEST TRUCK STATUS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 TCI MANUAL TEST SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 PTU BROWSER PSC CONFIGURATION MENU ACCESS SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . 71 INVERTER PARAMETERS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 SELF LOAD ENGINE TEST SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 TCI STAT_MENU SELECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 VIEW COUNTERS SCREEN EXAMPLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 MINE COUNTERS SCREEN (PSC_STATS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 VIEW PROFILES SCREEN EXAMPLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 MINE PROFILES SCREEN (PSC_STATS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 STAT SERIAL REPORT SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 RESET STATS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 STAT PROFILE MINE RESET SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 RESET BOX QUESTION SELECTION SCREENS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 DID PANEL IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 DID PANEL EXAMPLE NORMAL DISPLAY (NO FAULTS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 DID PANEL MESSAGE EXAMPLE FAULTS DISPLAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 DID PANEL MESSAGE EXAMPLE FAULTS DISPLAY FUNCTION KEYS. . . . . . . . . . . . . . . . . . . . . . 117 DID PANEL MESSAGE EXAMPLE FAULT RESET FUNCTION KEYS. . . . . . . . . . . . . . . . . . . . . . . . . 118 DID PANEL MESSAGE EXAMPLE TEST DISPLAY FUNCTION KEYS. . . . . . . . . . . . . . . . . . . . . . . . . 118 DID PANEL MESSAGE EXAMPLE LOAD BOX TEST FUNCTION KEYS. . . . . . . . . . . . . . . . . . . . . . . 119 DID PANEL MESSAGE EXAMPLE LOAD BOX TEST DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 DID PANEL MESSAGE EXAMPLE PSC SOFTWARE VERSION DATA. . . . . . . . . . . . . . . . . . . . . . . . 120 DID PANEL MESSAGE EXAMPLE LINK CAPACITANCE TEST DATA. . . . . . . . . . . . . . . . . . . . . . . . . 121 DID PANEL MESSAGE EXAMPLE OVERSPEED SETTING DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 TCI EVENT_MENU SCREENS ACCESS SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 TCI EVENT SUMMARY SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 TCI TRIGGER DATA SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 TCI DATA PACKS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 RESET TCI EVENTS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 ERASE TCI EVENTS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 EVENTS & INV PARAMS SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 PSC CAPACITANCE TEST SCREEN ASSESS SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 CAPACITANCE TEST SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 17FB144 AND 17FB147 BOARD TROUBLESHOOTING PROCEDURE (SHEET 1 OF 2). . . . . . . . . . 151 17FB144 AND 17FB147 BOARD TROUBLESHOOTING PROCEDURE (SHEET 2 OF 2). . . . . . . . . . 152 COM1 SERIAL PORT WINDOW MESSAGE FOR PROPER OPERATION. . . . . . . . . . . . . . . . . . . . . . . 153 HYPERTERMINAL ICON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 HYPERTERMINAL NEW CONNECTION WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 HYPERTERMINAL CONNECT TO WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 HYPERTERMINAL COM1 PROPERTIES WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
LIST OF ILLUSTRATIONS (Contd)

Fig. 87. 88. 89. 90. 91. 92. 93. No. Description Page HYPERTERMINAL MAIN WINDOW WHEN CONNECTED TO COM1 PORT. . . . . . . . . . . . . . . . . . . . . 157 HYPERTERMINAL MAIN WINDOW WHEN NOT CONNECTED TO COM1 PORT. . . . . . . . . . . . . . . . 158 HYPERTERMINAL MAIN WINDOW AFTER CYCLING CONTROL POWER, PROGRAM INSTALLED AND RUNNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 HYPERTERMINAL MAIN WINDOW AFTER CYCLING CONTROL POWER, PROGRAM NOT INSTALLED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 HYPERTERMINAL MAIN WINDOW AFTER CYCLING CONTROL POWER, WITH TAB KEY HELD DOWN (INTERRUPTING BOOTUP ROUTINE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 HYPERTERMINAL MAIN WINDOW AFTER ERASING CPU BOARD FLASH MEMORY. . . . . . . . . . . 162 HYPERTERMINAL MAIN WINDOW WHEN BOOTUP DOES NOT RUN DUE TO OPEN PTU SERIAL CABLE GROUND WIRE WITH THE PTU CONNECTED. . . . . . . . . . . . . . . . . . . . . . . . . . 163
vii
viii
1. OVERVIEW
This document describes the recommended truck startup and checkout procedures at an Original Equipment Manufacturer (OEM) facility or a customers mine. Special programming of specific mine software requirements, software updating, system verification procedures, and troubleshooting information are also included. Information on the screen content and functions of the wPTUt* Toolbox are also provided. Complete wPTUt Toolbox operational procedures are in the OHV wPTUt TOOLBOX USERS GUIDE, GEK91712.
1.1.
TOOLS AND TEST EQUIPMENT
The following are recommended tools and test equipment used in the startup and troubleshooting of the AC Off Highway Vehicle (OHV) propulsion system: 1. 2. 3. 4. 5. 6. Simpson Multimeter or Digital Multimeter Megger**, 0 to 1500 volt max. (02000 Megohms) @ 2 mA max. Portable Test Unit (PTU) loaded with GE Transportation Systems (GETS) OHV wPTUt Toolbox software. PTU cable, 9pin RS232 communications cable with 1 male end connector and 1 female end connector 1/4 in. thin wall socket Connector pin extraction and insertion tooling as follows: a. Pin Extraction, Amp Pt. 305183 b. Pin Insertion, Amp Pt. 910021 c. Pin Insertion, Amp Pt. 2008932 (for highdensity 104 pin connectors) d. Pin Extraction, PeiGenesis (ITT Cannon distributor) Pt. CETF8016 (external control e. Pin Insertion, PeiGenesis (ITT Cannon distributor) Pt. CITF8016 (for external control cabinet connectors) 7. Fluke 89 IV or equivalent with capacitance measurement capability.
NOTE: If a need arises to disassemble one of the multipin connectors to an electronic control card panel, a special thin wall socket or nut driver will be required to loosen and remove the assembly hardware. The socket can be purchased. However, if not purchased, it is recommended that a standard 1/4 in. socket or nut driver be sufficiently machined on a grinder to enable its use in performing the disassembly.
1.2.
HANDLING ELECTRONIC PANEL PRINTED CIRCUIT CARDS
CAUTION: It is important to note that printed circuit cards in the electronic control card panels are sensitive to static electricity. Handling cards without proper grounding precautions could damage electronic components mounted on them. Also, when transporting or storing these cards, industry recommended special static electricityproof containers should be used.
* Trademark of GE Transportation Systems ** Trademark of James G. Biddle Co. 1
2. PORTABLE TEST UNIT (PTU) DESCRIPTION
The PTU presently used by all GE field personnel is an IBM compatible, portable PC with a hard disk, compact disc (CD), 3.5 floppy diskette drive(s), and RS232 communication port. Any PC to be used with the wPTUt Toolbox should have a 500 MHz or higher processor speed and at least 128 Meg of random access memory (RAM). The wPTUt 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 trucks control system can be made through this PTU when loaded with the OHV wPTUt Toolbox software.
NOTE: Refer to GEK91712, OHV wPTUt Users Guide, for complete information on installing and using the wPTUt 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 specific mine operating parameters.
2.1.
wPTUt ABBREVIATIONS
There may be wPTUt abbreviations and terminology that are not familiar to the user. To help with understanding these, the wPTUt Toolbox software includes 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 wPTUt TOOLBOX OVERVIEW
NOTE: Refer to GEK91712, OHV wPTUt Users Guide, for complete information on installing and using the wPTUt Toolbox software. Information on screen selections, navigation methods, and options is also included.
The wPTUt Toolbox includes the major functions described in this section.
2.2.1. RealTime Data

The wPTUt 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 realtime data can be stored on the laptop for future use.
2.2.2. Stored Event Data

The wPTUt Toolbox can view and manipulate previously stored propulsion system information stored through the onboard diagnostic system. Event data can be viewed in many formats including summaries or more detailed frame byframe snapshots.
2.2.3. Statistical Data

The wPTUt Toolbox can be used to view statistical information stored by the propulsion systems onboard statistical manager. Numerous aspects of propulsion system operation are tracked and can be viewed on the screen as well as downloaded to the laptop for analysis offboard. 3
2.2.4. Setting Propulsion System Configuration Options

The wPTUt 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. Software Downloading

The wPTUt Toolbox is used to download system software and configuration files to the propulsion systems central processing unit (CPU) cards. The propulsion system controller (PSC), truck control interface (TCI), and Inverter software can be downloaded in a simple onestep process.
2.2.6. Data Analysis

The wPTUt Toolbox software contains an integrated graphing package that allows all of the system data to be graphed for more detailed analysis. Realtime 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 Variable (CSV) format for use by thirdparty software packages such as spreadsheets.
2.2.7. System Configuration

Many propulsion system parameters can be modified such as setting the onboard time and date, setting test analog outputs, data logger setup, and system parameter modification.
2.2.8. SelfTest
The wPTUt Toolbox software can be used to initiate or view propulsion system test information. Loadbox mode, the capacitance test, and manual selftest mode can be monitored.
2.2.9. Integrated Help

The wPTUt Toolbox software contains three levels of user help. Application help is available for major wPTUt 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. Mouseover help also provides a short description of each screen field.
2.2.10.
OneStep Downloading
All possible data to download from a truck, including event summaries, fivesecond data packs, and statistical data can be downloaded with the touch of a button. This insures that the right information is gathered.
2.3.
wPTUt SCREEN SELECTIONS
An outline of the wPTUt startup screen selections is shown in Figure 1.
NOTE: Refer to GEK91712, OHV wPTUt Users Guide, Sections 3.1 and 3.2 for complete information on installing and starting the wPTUt Toolbox software.
The Mode Options are either Normal Mode or Offline/Training Mode. In the Normal Mode the wPTUt attempts a connection with the target. When the connection is established, the truck type and truck ID are obtained from the target. (The mode options can be saved in a settings file.)
NOTE: The Truck Type, Panel Type, and GE System are disabled in the Normal Mode. In the Offline/Training 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
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 (wPTUt 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 wPTUt Startup and Communication) Exit
FIG. 1. wPTUt STARTUP SCREEN SELECTIONS. E44409B.
When the LOGIN to wPTUt Toolbox 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 and 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 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 wPTUt toolbox. Figure 1 through Figure 3 in this publication provide a reference to the figures associated with the various wPTUt screens to guide the user to the desired wPTUt function screen.
NOTE: A brief description of all wPTUt screens in contained in the Help menu. In the Menu Bar, click on Help > Applications > PTU Screen Help > Desired Screen.
PTU Screens TCI Normal_Operation Real_Time (Fig. 45) TCI Real Time Data (Fig. 46) TCI Serial Link Data TCI Analog Inputs (Fig. 37) TCI Temperatures Logic (Fig. 12) Accel Inhibit Logic (Fig. 13) Configuration TCI Parameters TCI Analog Outputs TCI Truck Configs TCI Software Versions TCI Datalog Setup Special Tasks Event_Menu (Fig. 72) TCI Event Summary (Fig. 73) TCI Trigger Data (Fig. 74) TCI Datapacks (Fig. 75) TCI Log Events Reset TCI Events (Fig. 76) Erase 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 and Date (Fig. 30) Events & Inv Params (Fig. 78) Engine_Stopped_Tasks (Fig. 41) TCI Manual Test (Fig. 48) Gauge Calibration (Fig. 42) Ctrl_Z_to_return_to_menu
FIG. 2. TCI WINDOW BROWSER SCREEN SELECTIONS. E44410B.
PTU Screens PSC Normal_Operation Real_Time (Fig. 38) PSC Real 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 (Fig. 51) Temperatures Capacitance Test (Fig. 80) Special Tasks (Fig. 43) Event_Menu PSC Event Summary PSC Trigger Data PSC Datapacks PSC Log Events Reset PSC Events Erase PSC Events Set Time and Date (Fig. 44) Events & Inv Params (Fig. 78) Engine_Stopped_Tasks (Fig. 34) PSC Manual Test (Fig. 35) Ctrl_Z_to_return_to_menu
FIG. 3. PSC WINDOW BROWSER SCREEN SELECTIONS. E44411B.
FIG. 4. wPTUt TOOLBOX STARTUP SCREEN. E44340B.
2.4.
wPTUt STARTUP SCREEN
The wPTUt Toolbox Startup screen is the initial selection screen that is displayed on the PC when the AC wPTUt Toolbox is commanded (after splash screen). It is from this screen that access to all other operating menus is 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 the Normal Mode (connected to a truck), these selections are performed automatically by the wPTUt 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.
NOTE: Refer to GEK91712, OHV wPTUt Users Guide, for complete information on installing and using the wPTUt Toolbox software. Information on screen selections, navigation methods, and options is also included.
2.5.
VIEW DATALOGGER AND DATA GRAPH SCREENS
Datalogger and Graph Data functions are contained in the GE OHV wPTUt Toolbox (GEOHVPTU 1.0). Use either of these functions as follows: 1. 2. Connect the PTU to the desired panel, start the GE OHV PTU Toolbox, and enter a valid password. Click on the AC Configuration Utility icon on the desktop or from the Start Menu go to START > Programs > GEOHVPTU 1.0 > AC Tools > Datalog > Start Datalogger (or Graph Data). Close the Datalogger or Graph Data display screen by clicking on the X in the upper right corner of the screen.
3.
2.6.
SAVING SCREEN DISPLAYS
Any real time screen display can be saved for future viewing. Complete procedures for saving screens and data are provided in GEK91712, OHV wPTUt Toolbox Users Guide, Section 3.5, MAIN WINDOW MENUS. A saved screen can be replayed in both online and offline modes. The screens can be saved to a file and 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 wPTUt toolbox (Fig. 5). Refer to GEK91712, OHV wPTUt Toolbox Users Guide, Section 5, PASSWORD UTILITY for complete information on setting passwords and password privilege levels. It is recommended that supervisors assign passwords and privilege levels below their own.
NOTE: On some PTUs, difficulty has been experienced if passwords were entered 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 characters.
FIG. 5. START MENU PASSWORD UTILITY. E45148.
10
3. SELECTED SCREEN DESCRIPTIONS AND FUNCTIONS
The following information describes selected screens and functions that are commonly used in the startup and troubleshooting of the GE OHV AC Propulsion System. Sections 3.1 through 3.4 describe screens that are contained in the wPTUt Configuration Utility. Sections 3.5 through 3.8 describe screens and functions that are contained in the wPTUt Toolbox . The propulsion systems REST mode function is described in Section 3.9.
3.1.
PRODUCT SERVICE DATA SCREEN
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 been authorized and activated can be set or changed. Perform the following to change the data settings: 1. 2. 3. Either click in the desired box (outlined in red on the left of screen) or use the TAB key to scroll continuously down through the boxes. Change the setting by deleting the existing setting (press any key and type the new setting, or simply type over the existing data). 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. Popup messages notify the user that the changed data has been saved, and offer other Save options.
3.2.
TRUCK SPECIFIC DATA SCREEN
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 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. 2. 3. Either click in the desired box (outlined in red on the left of screen) or use the TAB key to scroll continuously down through the boxes. Change the setting by deleting the existing setting (press any key and type the new setting, or simply type over the existing data). 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 Specific Data screen and correct the setting.
11
NOTE: To keep the changes made to the Truck Specific Data settings, the file must be saved.
4. Click on File and Save. Popup messages notify the user that the changed data has been saved, and offer other Save options.
The Truck Specific Data screen is used to enter the following information: 1. Percent retard pedal travel indicating retard request OFF S 2. This is the percent of pot reference volts at which the control is calibrated to have zero retard request. See section, Foot Pedal Adjustments.
Percent retard pedal travel indicating retard request FULL ON S This is the percent of pot reference volts at which the control is calibrated to have full retard request. See section, Foot Pedal Adjustments.
3.
Percent retard lever travel indicating retard request OFF S 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 retard lever travel indicating retard request FULL ON S 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.
Hydraulic brake temperature meter scale factor S This a value from 0.0 to 1.0 that calibrates the meter reading against actual temperature. See section, Meter Scale Adjustments.
6.
Propulsion system temperature meter scale factor S This a value from 0.0 to 1.0 that calibrates the meter reading against actual temperature. See section, Meter Scale Adjustments.
7.
Percent accel pedal travel indicating accel request OFF S This is the percent of pot reference volts at which the control is calibrated to have zero accel request. See section, Foot Pedal Adjustments.
8.
Percent accel pedal travel indicating accel request FULL ON S This is the percent of pot reference volts at which the control is calibrated to have full accel request. See section, Foot Pedal Adjustments.
9.
Truck identification number S This is for the mine to enter the truck identification number. Truck ID shows up with the event data and must be unique for each truck.
3.3.
VIEW OVERSPEEDS SCREEN
The View Overspeeds screen displays the current mine speed limit settings for the truck chosen (Fig. 26).
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3.4.
SET WHEEL MOTOR TYPES SCREEN
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 series 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. 2. 3. 4. Either click in the desired box (outlined in red on the left of screen) or use the TAB key to toggle between the boxes. Change the setting by deleting the existing setting (press any key and type the new setting, or simply type over the existing data). 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.) Click on File and Save. Popup messages notify the user that the changed data has been saved, and offer other Save options.
3.5.
MONITOR REAL TIME DATA
Real time data for both PSC and TCI can be viewed by using the wPTUt. The PSC and TCI procedures and screens are very similar and only require wPTUt connection to the desired serial port in the operator cab. Perform the following to monitor PSC real time data: 1. 2. 3. Connect the wPTUt to the PSC serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select PSC Panel, select appropriate truck type, and click on LOGIN to wPTU Toolbox . From the window browser, select PTU Screens > PSC > Normal_Operation > Real_Time > PSC Real Time Data (Fig. 38). The PSC Real Time Data screen is now displayed (Fig. 40).
3.5.1. PSC Real Time Data Screen

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 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. 2. Analogs This section monitors the status and values of analog signals from devices such as current sensors, voltage sensors, temperature sensors, etc. 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. 13
3.
Speeds This section monitors various speed sensor signals and provides a processed truck speed indication.
NOTE: When discrete signals are active, they are displayed inversed (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 position sensors, electronic connector continuity, selector switch status, etc. 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. Serial from TCI This section monitors the status of discrete signals received by PSC from TCI over the PSC TCI serial link. Serial to TCI This section monitors the status of discrete signals provided by PSC to TCI over the PSCTCI serial link. Inverters This section monitors the status of various signals related to inverter operation including run status, torque command, torque feedback, etc.
5.
6.
7.
8.
Close the PSC Real Time Data display screen by clicking on the X in the upper right corner of the screen.
3.5.2. PSC Serial Link Data Screen

1. 2. From the window browser, select PTU Screens > PSC > Normal_Operation > Real_Time > PSC Serial Link Data (Fig. 38). 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. PSC Analog Inputs Screen

1. 2. From the window browser, select PTU Screens > PSC > Normal_Operation > Real_Time > PSC Analog Inputs (Fig. 38). The PSC Analog Inputs screen is now displayed (Fig. 39). This screen monitors the status of all analog input signals to PSC. 3. Close the PSC Analog Inputs display screen by clicking on the X in the upper right corner of the screen.
3.5.4. PSC Temperatures Screen

1. 2. From the window browser, select PTU Screens > PSC > Normal_Operation > Real_Time > PSC Temperatures (Fig. 38). The PSC Temperatures screen is now displayed (Fig. 7). This screen monitors the status of various component temperatures provided either by sensors or by calculations. 3. 14 Close the PSC Temperatures display screen by clicking on the X in the upper right corner of the screen.
FIG. 6. PSC SERIAL LINK DATA SCREEN. E44390B.
15
FIG. 7. PSC TEMPERATURES SCREEN. E44392B.
16
3.6.
CHECK PSC MODE LOGIC OPERATION
The PSC Logic screens can be accessed by the wPTUt user to check PSC Ready Mode, Propel Mode, and Retard Mode operation. These screens display realtime ladder diagrams which show the necessary truck functions and propulsion system operations that must occur in order to achieve the operating mode selected. When activated, the various ladder diagram functions are displayed reversed (highlighted). In this manner, these logic screens can be used as a troubleshooting aid in diagnosing why the propulsion system does not achieve a commanded mode of operation.
3.6.1. Accessing PSC Logic Screens

Perform the following to access the PSC Logic screens: 1. 2. 3. Connect the wPTUt to the PSC serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select PSC Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox . From the window browser, select PTU Screens > PSC > Normal_Operation > Logic (Fig. 8). The PSC Logic menu of screens is now displayed. Doubleclick on the desired screen to display it.
3.6.1.1.
1. 2.
Ready Mode Logic Screen
From the Logic menu, doubleclick on Ready Mode to select that screen (Fig. 8). The Ready Mode screen is now displayed (Fig. 9). This screen displays the necessary requirements and the status of those requirements for the propulsion system to achieve the Ready Mode in preparation for either a subsequent Propel Mode or Retard Mode of operation.
3.
Close the Ready Mode display screen by clicking on the X in the upper right corner of the screen.
3.6.1.2.
1.
Propel Mode Logic Screen
From the Logic menu, doubleclick on Propel Mode to select that screen (Fig. 8).
FIG. 8. PSC LOGIC SCREENS ACCESS SEQUENCE. E45238.
17
FIG. 9. PSC READY MODE LOGIC SCREEN. E44395B.
FIG. 10. PSC PROPEL MODE LOGIC SCREEN. E44396B.

2. The Propel Mode screen is now displayed (Fig. 10). This screen displays the necessary requirements and the status of those requirements for the propulsion system to achieve the Propel Mode of operation. 18
3.
Close the Propel Mode display screen by clicking on the X in the upper right corner of the screen.
3.6.1.3.
1. 2.
Retard Mode Logic Screen
From the Logic menu, doubleclick on Retard Mode to select that screen (Fig. 8). The Retard Mode screen is now displayed (Fig. 11). This screen displays the necessary requirements and the status of those requirements for the propulsion system to achieve the Retard Mode of operation.
3. 4.
Close the Retard Mode display screen by clicking on the X in the upper right corner of the screen. Click on the Target button to go back to the GE OHV wPTUt Toolbox Login screen, close the wPTUt Toolbox, shut down the PTU, and disconnect it from the PSC serial port.
FIG. 11. PSC RETARD MODE LOGIC SCREEN. E44397B.
19
3.7.
CHECK TCI ACCEL INHIBIT LOGIC OPERATION
The TCI Accel Inhibit Logic screen can be accessed by the wPTUt user to check the TCI accel inhibit logic. This screen displays realtime 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, this logic screen can be used as a troubleshooting aid in diagnosing why an accel inhibit condition has occurred.
3.7.1. Accessing TCI Accel Inhibit Logic Screen

Perform the following to access the TCI Accel Inhibit Logic screen: 1. 2. 3. 4. 5. Connect the wPTUt to the TCI serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox . From the window browser, select PTU Screens > TCI > Normal_Operation > Logic > Accel Inhibit Logic (Fig. 12). The Accel Inhibit Logic screen is now displayed (Fig. 13). Close the Accel Inhibit Logic display screen by clicking on the X in the upper right corner of the screen. Click on the Target button to go back to the GE OHV wPTUt Toolbox Login screen, close the wPTUt Toolbox, shut down the PTU, and disconnect it from the TCI serial port.
FIG. 12. TCI ACCEL INHIBIT LOGIC SCREEN ACCESS SEQUENCE. E45239.
20
FIG. 13. TCI ACCEL INHIBIT LOGIC SCREEN. E44363A.
21
3.8.
CONSOLIDATED TRUCK DATA SAVE FUNCTION
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 wPTUt 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: 1. 2. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox . From the PTU Screens > TCI screen Menu Bar, select UpLoad > Consolidated Truck Data Save (Fig 14, refer to GEK91712).
NOTE: Files are normally uploaded to the following: c:/program files/geohvptu_xx/data_ac/<truck id date time>
3. 4. 5. Select the type of report to be saved from the Reports Type list, choose a Save Directory, then click on the Begin button to begin uploading (Fig. 15). Click on Close when the uploading is complete, then click on the Target button in the screen Tool Bar to go to the wPTUt startup screen. Close the wPTUt 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 subsequent manipulation
FIG. 14. CONSOLIDATED TRUCK DATA SAVE SELECTION FROM TOOLBAR. E45249.
22
FIG. 15. CONSOLIDATED TRUCK DATA SAVE SCREEN. E44354B.
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 removed from the DC link of the propulsion system, thereby preventing the propulsion system from either accelerating or retarding the truck. REST mode is commanded by applying the Parking Brake. Applying the Parking Brake commands 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 when shutting down a truck. The propulsion system should be placed in REST prior to turning off the engine. It should always be done when the operator leaves the operators cab. It is often done when the truck is expected to idle for an extended period of time. It is often done during the course of truck startup and troubleshooting.
2. 3. 4.
To bring the GE OHV AC propulsion system out of 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. CONFIGURATION FILES
Configuration files are contained in the GE Truck Configuration Utility (CFG AC Vxxxx) (current version). GE configuration file descriptions are displayed when this utility is opened. The configuration utility is opened and files selected as follows: 1. 2. 3. Click the mouse on 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). Select the appropriate GE configuration file for the truck (refer to Figure 20 for typical View Configuration Files screen example and refer to TABLE 1 for description of files). Click the on the file to select it and then click OK to go to the PTU Screens > Configuration Browser.
NOTE: A truck configuration file must be selected before any of the other utility menu choices can be used except Exit.
4.1.
GE CONFIGURATION FILE NAME DESCRIPTION
Configuration file names are established using a specific set of guidelines. Each element in a file name represents a piece of information which describes the application, revision, issue date, etc. (Fig. 16).
4.2.
VIEW TRUCK CONFIGURATION SCREEN
To view the Truck Configuration screen, from the window 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 A27 = AC 2700 HP OHV Propulsion System A35 = AC 3500 HP OHV Propulsion System A15 = AC 150 Ton OHV Propulsion System 005 A 9 03 Object Code Release Minor Version Number Least Significant Digit of Object Code Release Major Version Number Configuration File Revision Designation
Configuration File Number
FIG. 16. COMPOSITION OF A GE AC OHV CONFIGURATION FILE NAME. E44425B.
25
FIG. 17. TYPICAL TRUCK CONFIGURATION SCREEN. E44348B.
26
4.3.
GE/OEM DEFAULT CONFIGURATION FILES
There are 15 default GE configuration files for the OHV AC propulsion system. They are described in TABLE 1, Default Configuration Files and Descriptions.
NOTE: Files that do not apply to 150 Ton vehicles are shaded.
One OEM configuration file should be created by the GE Product Service representative or the OEM representative for each truck type at the mine location. The GE base configuration files in TABLE 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: S S 930E standard with DDC 4000 930E standard with Cummins QSK60
The OEM configuration files would be as shown in Figure 18.
GE Defaults
GE default file for standard 930E with DDC4000 A27006a.903
GE default file for standard 930E with QSK60 A27012a.903
OEM Files
OEM file with OEM options and mine information set OEM006a.903
OEM file with OEM options and mine information set OEM012a.903
Truck Files
Truck #. . . . Truck #. . . . Truck #. . . . Truck #. . . . Truck #5 . . . . with pedal settings etc. . . .
Truck #. . . . Truck #. . . . Truck #. . . . Truck #. . . . Truck #15 . . . . with pedal settings etc. . . .
FIG. 18. OEM TRUCK CONFIGURATION FILE TREE. E45286.
27
TABLE 1. DEFAULT 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 Engine, 31.5 Gear ratio
GE320AC 2700 HP DDC 4000 ENGINE 2. A27006a.903 3. a27007a.903 4. a27008a.903 5. a27009a.903 6. a27010a.903 7. a27011a.903 Standard Oil Sands Chuqui Freeport Freeport Autonomous KMS 930E Standard DDC Engine, 31.5 Gear ratio KMS 930E Oil Sands, DDC Engine 38.8 Gear ratio KMS 930E DDC Engine, 31.5 Gear ratio, 10,000 Ft. KMS 930E DDC Engine, 31.5 Gear ratio 14,000 Ft. KMS 930E DDC Engine, 38.5, Gear ratio 14,000 Ft. KMS 930E Autonomous, DDC, 31.5
GE320AC 2700 HP CUMMINS QSK60 Engine 8. a27012a.903 9. a27013a.903 10. a27014a.903 11. a27015a.903 12. a27016a.903 13. a27017a.903 GE320AC 3500HP 930E2SE 14. a35001a.903 Standard KMS 930E2SE, QSK78 engine, 32.6 Gear Ratio Standard Oil Sands Chuqui Freeport Freeport 2300NHP KMS 930E Standard QSK60 Engine, 31.5 Gear ratio KMS 930E Oil Sands, QSK60 Engine, 38.8 Gear ratio KMS 930E QSK60 Engine, 31.5 Gear ratio, 10,000 Ft. KMS 930E QSK60 Engine, 31.5 Gear ratio 14,000 Ft. KMS 930E QSK60 Engine, 38.8 Gear Ratio, 14,000 Ft. KMS 930E QSK60 Engine, 31.5 Gear ration 2300 NHP
GE150AC 150 Ton AC MT3300 15. a15001a.903 Standard Unit Rig MT3300, DDC12V engine, 28.8 Gear Ratio
28
4.4.
GE/OEM CONFIGURATION OPTIONS
These configuration options are adjustable only by an OEM or GE 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 password.
For Version 19, the features shown in TABLE 2, GE/OEM Configuration Options and Descriptions, are available as GE/OEM configurable options. Default settings are noted.
NOTE: Options that do not apply to 150 Ton vehicles are shaded.
TABLE 2. GE/OEM CONFIGURATION OPTIONS AND DESCRIPTIONS

# 1 2 OPTION NAME DESCRIPTION DEFAULT Disabled 10 mph Mine Adjustable Speed Limit Enables Overspeed Limits to be set by the Mine. OEM Speed Option 1 Sets the speed at which Digital Output #5 (TCI) is energized. The digital output signal is intended to be wired to an external light to give indication of truck speed. Sets the speed at which Digital Output #6 (TCI) is energized. The digital output signal is intended to be wired to an external light to give indication of truck speed. Sets the speed at which Digital Output #22 (TCI) is energized. The digital output signal can be used to drive other OEM devices based on engine speed.
OEM Speed Option 2
25 mph
Engine OEM speed option
1700 rpm
5 6 7
Dump Body UP Speed Limit Sets the speed limit applied to truck while dump body is UP. Dump Body UP Speed Limit Sets the speed limit applied to truck while dump body is (With Override) UP and the Override button is pressed. Dump Body UP RETARD Enable At Max Speed
5 mph 15 mph
Allows full speed control (PROPEL and RETARD effort 1 = Enabled modulation) at the maximum dump body UP speed. If disabled, RETARD is not automatically applied, only PROPEL effort is removed. Sets which type of axle box pressure sensor is present in the system. Set to 1 if an analog sensor is installed. Set to 2 if a digital sensor is installed. Without the option turned on, the propulsion system is unable to detect a loss of cooling air to the traction motors. 0 = None 1 = Analog 2 = Digital
Motor Pressure Event Enable
Second Language Support
Enables the second language support on the Diagnostic 1 = Enabled Information Display (DID) panel (disabled will hide the ESPANOL key )
29
TABLE 2. GE/OEM CONFIGURATION OPTIONS AND DESCRIPTIONS (Contd)

# 10 OPTION NAME Engine Cranking Protection Enabled DESCRIPTION Enables the engine cranking protection strategy, (i.e. 30 second max crank time, cooldown periods, etc.). DEFAULT 0 = Disabled
NOTE: This option should only be enabled on trucks with an MTU or DDC engine. The Cummins QSK60 engine has a prelube feature which requires additional time and will cause engine cranking to time out. Only QSK60 engines on trucks with KMS Truck Number 186 or greater should have this option enabled.
11 12 Engine Speed Limit and High Idle Enabled Hydraulic Brake Outlet Temp Monitor Deleted in Version 19 software. Enables monitoring of the hydraulic brake outlet cooling temperatures on a KMS 930E truck. To enable this option an updated FB160 card and the additional hydraulic sensors must be installed. 0 = Disabled
13
OEM Accel Inhibit
Enables the external OEM Accel Inhibit Logic. If this flag 0 = Disabled is set to 1, PSC Digital Input #16 is read to initiate an accel inhibit. Enables the Engine WarmUp Mode. Engine speed setting to use during Engine WarmUp Mode. Flag to indicate the wheel motor type of the left (driver side) wheel. 1 = 5GDY85A/B 2 = 5GDY85C 3 = 5GDY85D 4 = 5GDY85E 5 = 5GDY85F 11 = 5GDY106A 12 = 5GDY106B 21 = GEB23 22 = GEB25 0 = Disabled 1200 RPM Configuration Dependent
14 15 16
Engine WarmUp Mode Engine WarmUp Speed Left Wheel Motor Type
17 18
Right Wheel Motor Type RP1 HoldIn Strategy
Flag to indicate the wheel motor type of the right (passenger side) wheel. (See selections for Option 16.) Flag to indicate which RP1 HoldIn strategy to use. The RP1 HoldIn feature reduces the cycles during RETARD and helps reduce both RP1 and GY19 grid blower motor life. The three options are: 0 = None 1 = RETARD Mode 2 = READY Mode
Configuration Dependent 1 = RETARD
30
4.5.
SAVING NEW CONFIGURATION FILES
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 configuration 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 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 truck specific data.
4.6.
CONFIGURATION FILE DESTINATION DIRECTORY
The active wPTUt 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. 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.
CONFIGURATION FILE SOURCE DIRECTORY
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 that are available for retrieval and manipulation 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 PROPULSION SYSTEM SOFTWARE ON TRUCK
WARNING: Ensure that all mine, OEM, and GE safety procedures are followed during truck software installation. Ensure the truck is parked in a safe location with the Parking Brakes applied (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 trucks propulsion system, configuration files must be created and truck specific parameters must be recorded. The following tasks must be completed in the order listed: 1. 2. 3. 4. 5. 6. Select a GE Configuration file Create a GE/OEM Options file Create a TruckSpecific file Save existing truck data (if applicable) Program the TCI, PSC, and Inverters Checkout to verify proper software installation
NOTE: The OEM file only needs to be created one time. A truckspecific file must be created for each individual truck. The full installation process takes approximately 40 minutes.
5.1.
SELECTING THE GE CONFIGURATION FILE
NOTE: An appropriate level password is required to enter the Configuration tool.

1. Choose the appropriate GE configuration file. a. Click on the AC Configuration Utility icon on the desktop or from the Start Menu go to START > Programs > GEOHVPTU xx (current version) > AC Tools > CFG AC Vxxxx (current version) (Fig. 19). b. Select the 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 the file to select it and then click OK to go to the PTU Screens > Configuration Browser (Fig. 21). 2. Set the appropriate GE/OEM options for the mine location. a. From the PTU Screens > Configuration Browser, select Set GE/OEM Options. b. Set the appropriate options for the specific mine environment. Section 4., TABLE 2, GE/OEM Configuration 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. From the PTU Screens > Configuration Browser, select Set Wheel Motor Types. e. Enter the number corresponding to the left and right wheel motor types, then click on the X in the upper right corner of the screen to close it (Fig. 23).
33
f. From the PTU Screens > Configuration Browser, select Product Service Data (Fig. 24). Set the following items in this screen and press ENTER after each change/entry: (1) Mine Name (2) GE Mine Code (3) Model of Truck g. Name the OEM configuration file according to the following convention and save the file. Replace the first three digits of the GE configuration file with OEM. For example, OEM006a.903 would be the OEM configuration file that is derived from GE configuration file A27006a.903.
FIG. 19. OPEN AC CONFIGURATION TOOL SEQUENCE. E44345A.

34
FIG. 20. VIEW CONFIGURATION FILES SCREEN EXAMPLE. E44347A.
35
FIG. 21. PTU SCREENS CONFIGURATION BROWSER. E45203.
FIG. 22. SET GE / OEM OPTIONS SCREEN. E44351B.

36
FIG. 23. SET WHEEL MOTOR TYPES SCREEN. E45204.
FIG. 24. GE PRODUCT SERVICE DATA SCREEN. E44352B.
37
5.2.
1. 2. 3. 4. 5. 6. 7. 8.
CREATE THE TRUCK/MINE CONFIGURATION FILE

Determine and record the pedal, potentiometer (pot), and lever adjustment parameters according to the procedure described in Section 6.8., PEDAL, POT, AND LEVER ADJUSTMENT CHECKS. Determine and record the gauge calibration adjustment parameters according to the procedure described in Section 6.9., GAUGE CALIBRATION CHECKS. Click on 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) (Fig. 19). Select 0 Select a truck configuration, and choose the appropriate GE/OEM configuration file (created previously, Figure 20). Click on the OK button to go to the PTU Screens > Configuration Browser. From the PTU Screens > Configuration Browser, select Product Service Data. The Product Service Data screen is now displayed (Fig. 24). Set the following items in this screen and press ENTER after each change/entry: a. OEM Truck Serial Number b. OEM Ship Date c. In Service Date
9.
Close the Product Service Data screen by clicking on the X in the upper right corner of the screen.
10. From the PTU Screens > Configuration Browser, select Truck Specific Data. 11. The Truck Specific Data screen is now displayed (Fig. 25). 12. Enter the Pedal and Gauge settings that were calculated previously and the truck number and press ENTER after each change/entry.
FIG. 25. TRUCK SPECIFIC DATA SCREEN. E45206.
38
FIG. 26. OVERSPEEDS SCREEN. E44561A.

13. Close the Truck Specific Data screen by clicking on the X in the upper right corner of the screen. 14. If minesettable speed limit is enabled, set the proper overspeeds as follows: a. From the PTU Screens > Configuration Browser, select Overspeeds. b. The View Overspeeds screen is now displayed (Fig. 26). c. Enter the desired overspeed values and press ENTER after each change/entry. d. Close the View Overspeeds screen by clicking on the X in the upper right corner of the screen. 15. Save the file to a truckspecific file name; acw1903.xxx is recommended, where xxx is the truck number.
5.3.
SAVE EXISTING TRUCK DATA (Not Applicable to New Trucks)
For trucks that have had previous software installed, the trucks event and statistical data should be saved prior to downloading new software. (Also refer to Section 3.8., Consolidated Truck Data Save Function.) 1. 2. 3. 4. 5. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox . From the PTU Screens > TCI screen Menu Bar, select UpLoad > Consolidated Truck Data Save (Fig 14, also refer to GEK91712). Select All Reports, choose a Save Directory, then click on the Begin button to begin uploading (Fig. 15). Click on Close when the uploading is complete. Click on the Target button to go back to the GE OHV wPTUt Toolbox Login screen, close the wPTUt Toolbox, shut down the PTU, and disconnect it from the TCI serial port.
39
5.4.
1. 2. 3. 4.
PROGRAM TCI
Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, and click on the Program Panel button (Fig. 4). From the OHV PTU Toolbox Programming Utility screen, under AC Drive Systems, ALL, select TCI (Fig. 27). Select the appropriate configuration file from the Select Configuration File menu by clicking Browse to open the menu, then clicking on the desired file. Click on the Begin Download button to start downloading and automatically open the Programming the Panel status screen (Fig. 28). The OHV wPTUt Toolbox Programming Utility will automatically download the TCI with the latest TCI software and the chosen configuration file.
NOTE: It may be necessary to cycle control power in order to download. Do so by turning the Control Power Switch or Keyswitch OFF, then back ON.
5. 6. Click on the Exit button when the download is complete to go back to the OHV wPTUt Programming Utility screen. Click on the Exit button again to go back to the GE OHV wPTUt Toolbox Login screen, then close the wPTUt Toolbox, shut down the PTU, and disconnect it from the TCI serial port.
FIG. 27. OHV PTU PROGRAMMING UTILITY SCREEN. E44355B.
40
5.5.
1. 2. 3. 4.
PROGRAM PSC
Connect the PTU to the PSC serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, and click on the Program Panel button (Fig. 4). From the OHV wPTUt Toolbox Programming Utility screen, under AC Drive Systems, ALL, select PSC (Fig. 27). Select the appropriate configuration file from the Select Configuration File menu by clicking Browse to open the menu, then clicking on the desired file. Click on the Begin Download button to start downloading and automatically open the Programming the Panel status screen (Fig. 28). The OHV wPTUt Toolbox Programming Utility will automatically download the PSC with the latest PSC software and the chosen configuration file.
5. 6. Click on the Exit button when the download is complete to go back to the OHV wPTUt Programming Utility screen. Click on the Exit button again to go back to the GE OHV wPTUt Toolbox Login screen, then close the wPTUt Toolbox, shut down the PTU, and disconnect it from the PSC serial port.
FIG. 28. PROGRAMMING THE PANEL STATUS SCREEN. E44356B.
41
5.6.
1. 2. 3. 4. 5. 6. 7.
PROGRAM INVERTERS
Apply the Parking Brake (propulsion system commanded to REST mode). Open the control cabinet door and set the Ground Fault Cutout switch to the CUTOUT (Down) position. Check the link charged lights and verify the link is discharged. Connect the PTU to the CNG (Inverter #1) serial port located inside the group, start the GE OHV wPTUt Toolbox, enter password, and click on the Program Panel button (Fig. 4). From the OHV wPTUt Toolbox Programming Utility screen, under AC Drive Systems, GE150AC, select Inverter (Fig. 27). Select the appropriate object file from the Select Object File menu by clicking Browse to open the menu, then clicking on the desired file. Click on the Begin Download button to start downloading and automatically open the Programming the Panel status screen (Fig. 28). The OHV wPTUt Toolbox Programming Utility will automatically download the connected inverter with the latest software and the chosen object file.
8. 9. Click on the Exit button when the download is complete to go back to the OHV wPTUt Programming Utility screen. Click on the Exit button again to go back to the GE OHV wPTUt Toolbox Login screen and disconnect the wPTUt from the CNG (Inverter #1) serial port.
10. Connect the wPTUt to the CNH (Inverter #2) serial port and repeat steps 5 through 9 of this procedure. 11. Click on the Exit button again to go back to the GE OHV wPTUt Toolbox Login screen, then close the wPTUt Toolbox, shut down the PTU, and disconnect it from the CNH (Inverter #2) serial port. 12. Set the Ground Fault Cutout switch back to the NORMAL (Up) position and close the control cabinet door.
5.7.
CHECKOUT
Verify proper software installation by performing the following steps: 1. 2. 3. 4. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox . From the window browser, select PTU Screens > TCI > Normal_Operation > Configuration > TCI SW Versions. The TCI SW Versions screen is now displayed (Fig. 29). Verify the following version information on the display screen: TCI VER: {current version}
TRUCK TYPE: {150 ton} TRUCK ID: 5. 6. {current truck}
Close the TCI SW Versions display screen by clicking on the X in the upper right corner of the screen. Verify the TCIs time is set correctly as follows: a. From the window browser, select PTU Screens > TCI > Special_Tasks > Set Time and Date.
42
FIG. 29. TCI SW VERSIONS SCREEN. E45255.
FIG. 30. TCI SET TIME AND DATE SCREEN. E44380A.

b. The Set Time and Date screen is now displayed (Fig. 30) c. Correct the date and time setting as necessary and click on SET CLOCK to enter the changes. d. Close the Set Time and Date display screen by clicking on the X in the upper right corner of the screen. 7. Reset the TCIs event information as follows: (Fig. 31) a. From the window browser, select PTU Screens > TCI > Special_Tasks > Event_Menu > Reset TCI Events. b. The RESET the Active TCI Events selection screen is now displayed. c. Click on Yes to reset the events and close the screen. d. From the window browser, select 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. E44367A.

f. Click on Yes to erase the events and close the screen.
NOTE: The following step must be performed the first time V19 or higher software is installed due to the additional counter categories (yesterday, last month, this month). This step is not required for subsequent software downloads.
8. Reset the TCIs Statistical Information as follows: (Fig. 32) a. From the window browser, select PTU Screens > TCI > Special_Tasks > Stat_Menu > Reset Stats. b. The Reset Stats screen is now displayed. c. Click on the selection box for Reset ALL <GE AND MINES> Statistics and click on Yes in the question window that pops up. d. Close the Reset Stats display screen by clicking on the X in the upper right corner of the screen. 9. Click on the Target button to go back to the GE OHV wPTUt Toolbox Login screen and disconnect the wPTUt from the TCI serial port.
10. Connect the wPTUt to the PSC serial port (located in the operator cab) and click on LOGIN to wPTUt Toolbox.
FIG. 32. TCI RESET STATS SCREEN. E45208.
44
FIG. 33. PSC SOFTWARE VERSIONS SCREEN. E45209.

11. From the window browser, select PTU Screens > PSC > Normal_Operation > Configuration > PSC SW Versions. 12. The PSC SW Versions screen is now displayed (Fig. 33). 13. Verify the following version information on the display screen: PSC VER: {current version}
TRUCK TYPE: {150 ton} TRUCK ID: INV1 VER: INV2 VER: {current truck} {current version} {current version}
14. Close the PSC SW Versions display screen by clicking on the X in the upper right corner of the screen. 15. Reset the PSCs event information as follows: (similar to Fig. 31) a. From the window browser, select PTU Screens > PSC > Special_Tasks > Event_Menu > Reset PSC Events. b. The RESET the Active PSC Events selection screen is now displayed. c. Click on Yes to reset the events and close the screen. d. From the window browser, 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 are logged on the DID panel (refer to Section 8.2., Faults Display, for DID panel faults information). 17. From the window browser, select PTU Screens > PSC > Normal_Operations > Real_Time > PSC Real Time Data. 45
18. The PSC Real Time Data screen is now displayed (Fig. 40). 19. On the PSC Real Time Data screen, verify the following: S S ACCELSEL = 0.00 with the Accel Pedal at rest ACCELSEL = 1.00 with the Accel Pedal fully engaged
NOTE: The following verifications require that Service Brake/Wheel Lock/Load Brake is not applied. Ensure the Parking Brake is applied (propulsion system commanded to REST mode) and it is safe to remove the service brakes.
S S S RETRDSEL = 0.00 with the Retard Pedal and Lever (if equipped) set to the OFF position. RETRDSEL = 1.0 with the Retard Pedal at FULL. (If a 1 pedal system, ensure the service brake is not entered) RETRDSEL = 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 appropriate mine procedures, start the diesel engine. 22. Verify the System Mode is REST on the DID panel (refer to Section 8.1., Modes Display, for DID panel modes information). 23. Release the Parking Brake (propulsion system exits REST mode) and verify the System Mode changes to TEST, then READY within one minute. 24. With the brakes applied, move the Direction Selector handle to FORWARD and verify torque is present on each inverter (TQCMD1, TQCMD2, and TRQFB1, TRQFB2) shown on the PSC Real Time Data screen. 25. Verify no EVENTS are logged as follows: a. From the window 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 no EVENTS are logged, then close the PSC Events Summary display screen by clicking on the X in the upper right corner of the screen. 26. Return the Direction Selector handle to NEUTRAL. 27. Using the appropriate mine procedures, initiate Load Box operation through the wPTUt or DID panel (for wPTUt, 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 at full engine RPM for two minutes and verify that full horsepower is developed. 29. Verify no EVENTS log during Load Box Mode as follows: a. From the window 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 wPTUt for test). c. Verify that no EVENTS are logged, then close the PSC Events Summary display screen by clicking on the X in the upper right corner of the screen. 30. Exit Load Box. 31. Click on the Target button to go back to the GE OHV wPTUt Toolbox Login screen, then close the wPTUt Toolbox, shut down the PTU, and disconnect it from the PSC serial port. 46
6. TRUCK STARTUP PROCEDURES
6.1.
CIRCUIT CONTINUITY AND RESISTANCE CHECKS AND ADJUSTMENTS
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 voltohmmeter (VOM) that is set for resistance measurements.
WARNING: Electric shock can cause serious or fatal 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, but not be limited to, ensuring that all equipment is deenergized, including energy storage components such as capacitors.
6.1.1. VOM Circuit and Component Checks

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. Circuit/Component DC Link VOM Connection Note VOM Positive Lead Connection DC+ Link Bus Bar (Top Bus Bar) VOM Negative Lead Connection Cabinet Ground VOM Reading in Ohms (Approx.) 2800
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 (Bus Below DC+) VOM on R1 Scale to DC+ Link Bus Bar avoid charging capacitors VOM on R1 Scale to DC Link Bus Bar avoid charging capacitors Cabinet Ground DC Link Bus Bar 2800 Infinity
DC+ Link Bus Bar
5.5
47
6.2.
MEGGER TEST FOR GROUNDS
WARNING: Electric shock can cause serious or fatal injury. To avoid such injury, 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 modules and diodes across all coils: relays, contactors and reverser. If any are reversed, output channels on the digital input/output cards can be damaged during attempts at energization. CAUTION: A bell ringer must not be used for wiring checks; use an ohmmeter or light continuity 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. Preparation For Megger Test

Perform the following procedures to prepare the circuit categories for meggering by either removing wiring connections, insulating or jumpering, as indicated by the instructions. Use shorting wire for jumpering procedures, however, be careful not to short devices to ground or to the wrong devices. 1. 2. 3. 4. 5. Place both Inverter Cutout switches, located inside the main control cabinet, in the CUTOUT (down) position. Ensure that the Parking Brake is applied (propulsion system commanded to REST mode). Place the GF Cutout switch, located inside the main control cabinet, in the CUTOUT (down) position. Disconnect Battery Power. Disconnect the round power plug from the top of each phase and chopper module: PM1A+, PM1A, PM1B+, PM1B, PM1C+, PM1C, PM2A+, PM2A, PM2B+, PM2B, PM2C+, PM2C, CM1, CM2 6. 7. 8. Disconnect all 17FL375panel 104 pin connectors. Install a jumper between the positive and negative DC link bus bars in the control cabinet. Disconnect the CCLR1 and CCLR2 connectors which are located on the power cabinet ceiling above the AFSE panel. Disconnect the circular connectors from all VAMs.
9.
10. Remove all wires from ground block GNDB which is located to the left of the AFSE. 11. Remove the GF contactor arc chute and install a jumper between the main contactor tips on GF.
48
6.2.2. Megger Test Procedure

CAUTION: To prevent equipment damage, use a 1500 V DC max. @ 2 mA max. megger only.
6.2.2.1.
1. 2.
Main Power Circuit
Install a jumper from the GF main contactor tip to ground. Connect a megger between the power circuit DC positive bus bar and ground. Turn on the megger and test at 1500 V DC max. The reading should be approximately one megohm. Turn off and disconnect the megger.
3.
6.2.2.2.
1. 2. 3.
Alternator Field Circuit
Remove the jumper from the GF main contactor tip to ground. Install a jumper from the power circuit DC positive bus bar to ground. Connect a megger between the GF main contactor tip and ground. Turn on the megger and test at 1500 V DC max. The reading should be infinity. Turn off and disconnect the megger.
4.
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 several hours. Heat can be applied using several methods: 1) heat lamp, 2) hair dryer, 3) passing 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. Restore Circuitry

If no faults were found, remove shorting wires and reconnect all wires and cables previously disconnected for this test as follows: 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove the jumper wire between the GF contactor tips and reinstall the GF contactor arc chute. Remove the jumper wire from the power circuit DC positive bus bar to ground. Remove the jumper wire between the positive and negative DC link bus bars. Reconnect all wires previously removed from ground block GNDB. Reconnect the VAM connectors. Reconnect the CCLR1 and CCLR2 connectors. Reconnect all 17FL375 panel connectors. Reconnect the power plug to all phase and chopper modules. Reconnect Battery Power. 49
6.3.
1.
TROUBLESHOOTING FOR GROUNDS

Give the truck a quick visual inspection looking for the following: a. IMoisture, oil, or debris in or on motorized wheels, alternator, grid resistors, main control cabinet, and power cables b. Any wire or metal that might be touching exposed connections c. IFrayed or rubbing cables
2.
If the visual inspection does not locate the cause, follow the megger procedures to isolate the ground to one of the three major loops. Once the ground has been isolated to a particular loop, that loop should be broken down into smaller sections and remeggered.
3.
NOTE: Refer to the overall system schematic to obtain the most convenient points for subsection isolation. NOTE: This subdividing of the grounded section should continue until the ground is isolated in a particular cable or piece of equipment. Appropriate measures can then be taken.
4. If the ground occurs in a motorized wheel or alternator, the unit should be checked by removing all connections and remeggering. Perform a vigorous inspection of the unit following the guidelines of the inspection made in step 1. If no reason for the ground can be determined, or if the problem cannot be corrected, removal of the unit for repair at an authorized shop will be necessary. If the ground is isolated to the Dynamic Retarding Assembly, disconnect all cables leading to it and remegger the Dynamic Retarding Assembly. If the ground is still present, thoroughly inspect the Dynamic Retarding Assembly for any obvious problems such as frayed or rubbing cables and water or debris inside the Dynamic Retarding Assembly. If the inspection does not locate the cause, isolate the two halves of the Dynamic Retarding Assembly and remegger to localize the ground to one side or the other.
5. 6.
7.
8.
9.
10. On trucks equipped with a blown Dynamic Retarding Assembly, if the ground occurs on the blower motor side, disconnect the motor and check for grounds in the unit once again. 11. If the ground is still present in the Dynamic Retarding Assembly, it will be necessary to disconnect each resistor section until the grounded section is found.
50
6.4.
LOW VOLTAGE POWER SUPPLY CHECKS
6.4.1. Preparation for Power Supply Check

1. 2. Remove the 50 amp control circuit system fuse (BATFU) located near the bottom of the power section of the control cabinet behind the center door. Disconnect all the 17FL375 panel cards from their backplane connectors. Verify that all panel connectors are connected.
6.4.2. Power Supply Voltage 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, and replace components as required.
6.4.2.1.
1.
Battery
Turn the truck battery switch ON and check polarity of the battery voltage at the location where BATFU was removed. The BATFU input side should read positive, and the other side should read negative (battery common). Turn the truck battery switch OFF and reinstall the BATFU fuse. Turn the battery switches and the key switch in the operators cab ON to enable control power availability to the AC OHV propulsion system.
2. 3.
6.4.2.2.
1. 2.
System Power Supply
Turn the Control Power Switch (CPS, located inside of the main control cabinet) ON. On the FH41 Power Supply (located in control area of cabinet below the ICP panel), view the green status 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.
6.4.2.3.
DID Power Supply
Check that the DID panel is illuminated.
6.5.
1. 2. 3.
PSC AND TCI CARD CHECKS

Turn the CPS OFF. Verify that all ICP panel (17FL375) cards are properly installed and connected to the backplane of the panel. Locate the FAT1 LEDs at the bottom of the PSC CPU card (17FB147) and the TCI CPU card (17FB144) 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. If any LED remains illuminated, it may indicate either a bad CPU card or a problem with the +5V power supply in that panel. Determine the possible faulty card by turning the CPS 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. Failure to do so will result in card and/or panel equipment damage.
51
6.6.
LOAD AC OHV PROPULSION SYSTEM SOFTWARE
Refer to section, INSTALLING AC PROPULSION SYSTEM SOFTWARE ON TRUCK, for details regarding downloading of software into the AC OHV propulsion system.
6.7.
PSC MANUAL DIGITAL INPUT/OUTPUT TEST PROCEDURES
Perform the following procedure to manually check certain PSCcontrolled outputs and PSCmonitored inputs to verify proper wiring and component operation: 1. 2. 3. 4. 5. Apply the Parking Brake (propulsion system commanded to REST mode). Ensure engine is OFF. Connect the PTU to the PSC serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select PSC Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox . From the window browser, select PTU Screens > PSC > Engine_Stopped_Tasks > PSC Manual Test (Fig. 34). The PSC Manual Test screen is now displayed (Fig. 35).
FIG. 34. PTU BROWSER PSC MANUAL TEST SCREEN ACCESS SEQUENCE. E45224.
52
FIG. 35. PSC MANUAL TEST SCREEN. E44402A.
53
6.
Perform the following digital output checks from the PSC Manual Test screen: a. In the Toggle Digital Outputs (TDO) section of the screen, click on GF to highlight it. Verify that the GF contactor picks up and that GFFB is highlighted in the Digital Input (DI) section of this screen. Click on GF 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. Verify (visually) that the GFR contactor picks up. Click on GFR again in the TDO section of the screen to deenergize GFR. c. In the TDO section of the screen, click on RP1 to highlight 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 the TDO section of the screen, click on CPRL to highlight it. Verify that after turning the CPS OFF, control power remains applied to the AC OHV propulsion system. Turn CPS back to the ON 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 there is 24V DC to ground on the AFSEF1L and AFSEF2L wires on the AFSE 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 control cabinet is illuminated. Click on SYSFLT again in the TDO section of the screen to deenergize SYSFLT.
54
7.
Perform the following Digital Input checks: a. With the Keyswitch and the CPS ON, verify that the following Digital Inputs are illuminated: KEYSW, CPSFB, CNFB, CNIFB, CNXFB, and GFNCO . b. Move the Inverter #1 Cutout switch, located inside the control area, to the CUTOUT position, INV1CO should be highlighted. Move this switch back to the NORMAL position, INV1CO should then turn OFF. c. Move the Inverter #2 Cutout switch, located inside the control area to the CUTOUT position, INV2CO should be highlighted. Move this switch back to the NORMAL position, INV2CO should then turn OFF. d. Digital Input BRAKEKON will be highlighted if the Service Brake is engaged, otherwise, it will be off. e. Close the PSC Manual Test display screen by clicking on the X in the upper right corner of the screen.
8.
Click on the Target button to go back to the GE OHV wPTUt Toolbox Login screen, close the wPTUt Toolbox, shut down the PTU, and disconnect it from the TCI serial port.
55
6.8.
PEDAL, POT, AND LEVER ADJUSTMENT CHECKS
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. 2. 3. 4. 5. Remove control power from the AC OHV propulsion system. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox . Apply control power to the AC OHV propulsion system. From the window browser, select PTU Screens > TCI > Normal_Operation > Real_Time > TCI Analog Inputs (Fig. 36). The TCI Analog Inputs screen is now displayed (Fig. 37). Perform the following from this screen: a. Record the value for POTREF (typical value is 10.8 V). b. Record the value for ACCEL PEDAL with the pedal FULL OFF (typical value is 1.6 V). c. Record the value for ACCEL PEDAL with the pedal FULL ON (typical value is 8.5 V). d. Pull up on the Retard Speed Control Switch, and record the value for RSC POT with the knob turned FULLY CLOCKWISE (typical value is 0.1 V). e. Record the value for RSC POT with the knob turned FULLY COUNTERCLOCKWISE (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. 7. Click on the Target button to go back to the GE OHV wPTUt Toolbox Login screen, close the wPTUt Toolbox, shut down the PTU, and disconnect it from the TCI serial port. Connect the PTU to the PSC serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select PSC Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox .
FIG. 36. PTU BROWSER TCI REAL TIME MENU ACCESS SEQUENCE. E45225.
56
FIG. 37. TCI ANALOG INPUTS SCREEN. E44361A.
57
FIG. 38. PTU BROWSER PSC REAL TIME MENU ACCESS SEQUENCE. E44388B.
8. 9. From the window browser, select PTU Screens > PSC > Normal_Operation > Real_Time > PSC Analog Inputs (Fig. 38). The PSC Analog Inputs screen is now displayed (Fig. 39). Perform the following from this screen: a. Record the value for RETARD PEDAL with the pedal FULL OFF (typical value is 3.3 V). b. Record the value for RETARD PEDAL with the pedal FULL ON (typical value is 9.5 V). c. Close the PSC Analog Inputs display screen by clicking on the X in the upper right corner of the screen. 10. From the window browser, select PTU Screens > PSC > Normal_Operation > Real_Time > PSC Real Time Data (Fig. 38). 11. The PSC Real Time Data screen is now displayed (Fig. 40). Perform the following from this screen: a. With accel pedal FULLY RELEASED, verify that ACCELSEL = 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 / POT REF). Record this as the new CC_ACCEL_PEDAL_OFF_PCNT parameter value. b. With accel pedal FULLY PRESSED, verify that ACCELSEL = 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 pedal FULLY RELEASED, verify that RETRDSEL = 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 PEDAL OFF VOLTS / POT REF). Record this as the new CC_RETARD_PEDAL_OFF_PCNT parameter value. 58
d. With retard pedal FULLY PRESSED, verify that RETRDSEL = 1.00. If it is not, calculate the 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 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 FULLY CLOCKWISE (turned to TURTLE icon), verify that RETSPD = 0.0. f. With retard speed control knob PULLED OUT and knob turned FULLY CLOCKWISE (turned to RABBIT icon), verify that RETSPD > 36. g. Close the PSC Real Time Data display screen by clicking on the X in the upper right corner of the screen. 12. Click on the Target button to go back to the GE OHV wPTUt Toolbox Login screen, close the wPTUt Toolbox, shut down the PTU, and disconnect it from the PSC serial port.
FIG. 39. PSC ANALOG INPUT CHANNELS SCREEN. E44391A.
59
FIG. 40. PSC REAL TIME DATA SCREEN. E44389B.
60
FIG. 41. PTU BROWSER TCI GAUGE CALIBRATION SCREEN ACCESS SEQUENCE. E44382A.
6.9.
GAUGE CALIBRATION CHECKS
The following is the procedure for recording and checking the AC OHV propulsion system adjustments for the specific truck gauges: 1. 2. 3. 4. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox . From the window browser, select PTU Screens > TCI > Engine_Stopped_Tasks > Gauge Calibration (Fig. 41). The TCI Gauge Calibration screen is now displayed (Fig. 42). Enter a test speed of 10, 20, 30, or 40 MPH 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. CONFIGURATION CHANGES DUE TO CALIBRATION CHECKS

If, after performing the pedal, lever, pot, and gauge calibration checks, one or more configuration parameters required change, then do the following: 1. Change the affected truck specific parameters in the truck specific configuration file following the procedure in the section, CREATE THE TRUCK/MINE CONFIGURATION FILE. Download the software into the AC OHV propulsion system following those same procedures in the sections, PROGRAM TCI and PROGRAM PSC. After the new configuration has been downloaded, repeat the previous calibration checks to verify the new settings.
2.
3.
61
FIG. 42. TCI GAUGE CALIBRATION SCREEN. E44384A.
62
FIG. 43. PTU BROWSER SET TIME AND DATE SCREEN ACCESS SEQUENCES. E44366A.
6.11. SET TIME AND DATE

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 must be connected to the appropriate port in the operators cab. The following procedure is for TCI, but it is the 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.
1. 2. 3. 4. 5. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox . From the window browser, select PTU Screens > TCI > Special_Tasks > Set Time and Date (Fig. 43). The Set Time and Date screen is now displayed (Fig. 44). If the date and time displayed 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. 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. Repeat step 4 for each of the five windows. Click on 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 Verify that the time displayed in The NEW Date and time: line is correct. If not, repeat steps 5 through 7. Close the Set Time and Date display screen by clicking on the X in the upper right corner of the screen.
6. 7. 8. 9.
10. Click on the Target button to go back to the GE OHV wPTUt Toolbox Login screen, close the wPTUt Toolbox, shut down the PTU, and disconnect it from the TCI serial port. 63
FIG. 44. SET TIME AND DATE SCREEN. E45227.
64
FIG. 45. BROWSER TCI REAL TIME DATA SCREEN ACCESS SEQUENCES. E45231.
6.12. CHECK COMMUNICATION STATUS

The following procedure verifies that PSC and TCI are communicating properly with each other. 1. 2. 3. 4. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox . From the window browser, select PTU Screens > TCI > Normal_Operation > Real_Time > TCI Real Time Data (Fig. 45). The TCI Real Time Data screen is now displayed (Fig. 46). 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. If that does not clear the problem, then replace one CPU card at a time in order to determine the faulty card. 5. 6. 7. Close the TCI Real Time Data display screen by clicking on the X in the upper right corner of the screen. Click on the Target button to go back to the GE OHV wPTUt Toolbox Login screen, close the wPTUt Toolbox, shut down the PTU, and disconnect it from the TCI serial port. Connect the PTU to the PSC serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select PSC Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox . From the window browser, select PTU Screens > PSC > Normal_Operation > Real_Time > PSC Real Time Data (Fig. 38). The PSC Real Time Data screen is now displayed (Fig. 40).
8.
9.
10. In 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. If that does not clear the problem, then replace one CPU card at a time in order to determine the faulty card. 65
FIG. 46. TCI REAL TIME SCREEN. E44359A.

11. Close the PSC Real Time Data display screen by clicking on the X in the upper right corner of the screen. 12. Click on the Target button to go back to the GE OHV wPTUt Toolbox Login screen, close the wPTUt Toolbox, shut down the PTU, and disconnect it from the PSC serial port.
66
6.13. TCI ANALOG INPUT CHECKS

The following procedure verifies proper TCI analog input signal levels and measurements. If any of the following measurements differ significantly from their nominal values, check the signal source and wiring interface to TCI. If those check out OK, replace the TCI analog input card. 1. Connect the wPTUt to the TCI serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox . From the window browser, select PTU Screens > TCI > Normal_Operation > Real_Time > TCI Analog Inputs (Fig. 45). The TCI Analog Inputs screen is now displayed (Fig. 37). Check 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.) Measure the voltage at TB18 (wire number 10VDC) in the OEM electronics cabinet containing TCI shifter console.. This processed Pot Reference voltage should be approximately 11.0 V. Check the CONTROL BATT reading on the TCI Analog Inputs screen. It should be within 1.0 V of the measurement on the battery fuse panel located inside the control cabinet. Check the GROUND reading on the TCI Analog Inputs screen. It should be 0.0 V. Check the GAIN CHECK reading on the TCI Analog Inputs screen. It should be 10.0 V. Close the PSC Real Time Data display screen by clicking on the X in the upper right corner of the screen.
2.
3. 4.
5.
6.
7. 8. 9.
10. Click on the Target button to go back to the GE OHV wPTUt Toolbox Login screen, close the wPTUt Toolbox, shut down the PTU, and disconnect it from the TCI serial port.
6.14. TCI MANUAL DIGITAL OUTPUT CHECKS

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 with that device. If those check out OK, replace the appropriate TCI digital I/O card (consult system schematic to identify proper card). 1. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox . From the window browser, select PTU Screens > TCI > Engine_Stopped_Tasks > TCI Manual Test (Fig. 41).
2.
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). The TCI Manual Test screen is now displayed (Fig. 48).
4.
67
FIG. 47. TCI MANUAL TEST TRUCK STATUS SCREEN. E45232.
FIG. 48. TCI MANUAL TEST SCREEN. E44383B.
68
6.15. TCI MANUAL DIGITAL INPUT CHECKS

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 with that device. If those check out OK, replace the appropriate 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. 2. 3. When the Engine System Controller issues an Engine Caution output, ENGCAUTION should be displayed. When the Engine System Controller issues an Engine Warning output, ENGWARN should be displayed. When the Parking Brake is applied (propulsion system commanded to REST mode), PRKBRKFDBK should be displayed. When the Reset switch in the operator cab is actuated, RESET should be displayed. When the Direction Selector handle in the operator cab is moved to the FORWARD position, FORREQ should be displayed. When the Direction Selector handle in the operator cab is moved to the REVERSE position, REVREQ should be displayed. When any Engine Shutdown switch is actuated, ENGKILL should be displayed. When the Data Store switch in the operator cab is activated, DATASTORE should be displayed. When the dump body is down, BODYDWN should be displayed. When the dump body is raised, BODYDWN should no longer be displayed.
4. 5.
6.
7. 8. 9.
10. When the Load Brake is applied, LDBRK should be displayed. 11. When the Keyswitch is moved to the Engine Start position, ENGSTRTREQ should be displayed. 12. When the Retard Speed Control switch is pulled up, RSC should be displayed. 13. When the Payload Meter indicates that the truck payload is 25% of capacity or greater, FULLPAYLD 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 box is pressurized, AXLEP should be displayed. 15. When the Control Power Switch is turned to the ON position, CONTROLON should be displayed. 16. Close the TCI Manual Test display screen by clicking on the X in the upper right corner of the screen. 17. Click on the Target button to go back to the GE OHV wPTUt Toolbox Login screen, close the wPTUt Toolbox, shut down the PTU, and disconnect it from the TCI serial port.
69
6.16. DIAGNOSTIC INFORMATION DISPLAY (DID) PANEL CHECK

View the DID panel (17FM558). The cursor to the right of the event code should appear to spin. If it does not, remove power from the control system, then reapply power. If the problem persists, check that TCI is powered up and operational and check the wiring between TCI and the DID panel. If no problem is found there, first replace the TCI CPU card and then replace the DID panel until the problem is corrected.
6.17. INVERTER CHECKS

The following procedures verify proper inverter control operation. If a particular step of this procedure cannot be completed properly, replace the 17FB172 Inverter Control card(s).
NOTE: The HyperTerminal* application program must be running on the wPTUt before applying control power to the propulsion system. If not, the Inverter 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 wPTUt locks up or does not operate in an expected manner, type X three times in succession.
6.17.1.
1.
Inverter Phase Module Command and Feedback Circuitry Checks
Connect the PTU to the PSC serial port (located inside operator cab), start the GE OHV wPTUt Toolbox, enter password, select PSC Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox . From the window browser, select PTU Screens > PSC > Normal_Operation > Configuration > Inverter Parameters (Fig. 49). The Inverter Parameters screen is now displayed (Fig. 50).
2.
3.
NOTE: Parameter 25019 can only be changed through the 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. Change the parameter by typing 0 in the Inv # all, Value field and press ENTER. Close the Inverter Parameter display screen by clicking on the X in the upper right corner of the screen. Click on the Target button to go back to the GE OHV wPTUt Toolbox Login screen and click on Terminal Emulator Mode to start HyperTerminal. Disconnect the wPTUt serial cable from the PSC serial port and connect it to the CNG (Inverter #1) serial port. Press T to command the Inverter Test screen.
5. 6. 7. 8. 9.
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 on the GE150AC system are IGBTs. However, the inverter software refers to GTOs. For the purposes of this testing, the terms are used interchangably.
* Tradename of Hilgraeve Incorporated 70
FIG. 49. PTU BROWSER PSC CONFIGURATION MENU ACCESS SEQUENCE. E44387B.
FIG. 50. INVERTER PARAMETERS SCREEN. E45234.
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 corrected.
12. Perform the following GTO/IGBT module command and feedback checks: a. With the wPTUt 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. Move the > sign to the letter 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 in the feedback column should all turn to Fs. e. Repeat steps a through d for each phase module or chopper in Inverter #1. 13. Restore all settings by performing the following steps: a. With the wPTUt still connected to the CNG serial port, make certain that all T values are returned to F values. b. With the wPTUt still connected to the CNG serial port, press X until the prompt invcpu> appears. c. Disconnect the wPTUt serial cable from the CNG (Inverter #1) serial port and connect it to the PSC serial port. d. From the window browser, select PTU Screens > PSC > Normal_Operation > Configuration > Inverter Parameters (Fig. 50). e. Reset the parameters for Inverter #1 from the Inverter Parameters screen. 14. Close the Inverter Parameters display screen by clicking on the X in the upper right corner of the screen. 15. With the wPTUt connected to the PSC serial port, click on CMCTL to highlight and turn them ON, then press ENTER. 16. Disconnect the wPTUt serial cable from the PSC serial port and connect it to the CNH (Inverter #2) serial port. 17. Repeat steps 2 through 16 for Inverter #2 taking note of the following differences: All references to Inverter #1 are now for Inverter #2. All references to CNG are now for CNH. Shutdown the wPTUt Toolbox and turn the PTU off before disconnecting it in step 16, then do not reconnect it.
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6.18. SELF LOAD TESTING 6.18.1. Preparation for Self Load Testing
Perform the following steps prior energizing equipment for the purpose of self load testing: 1. 2. 3. Place both Inverter Cutout switches, located on the right hand side of the main control cabinet, in the CUTOUT (down) position. Apply the Parking Brake (propulsion system commanded to REST mode). Verify that all tape and/or other obstructions are removed from the contactor and control cabinet enclosures for proper air flow to the equipment.
WARNING: If a wheelmotor(s) has been removed, verify that its power cables are properly insulated in the 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 Testing.
4. 5. 6. Connect the PTU to the PSC serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select PSC Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox . From the window browser, select PTU Screens > PSC > Normal_Operation > Real_Time > PSC Real Time Data (Fig. 38). The PSC Real Time Data screen is now displayed (Fig. 40).
6.18.2.
Checks Prior to Self Load Testing
6.18.2.1. Battery Boost Check

WARNING: This procedure MUST be performed exactly as written. Failure to do so may result in personnel injury or death. The contactors in the contactor cabinet may be energized while the engine is running. The available potential even at engine idle is 700 volts at 180,000 amps.
1. 2. 3. 4. 5. Verify that engine is OFF. Apply the Parking Brake (propulsion system commanded to REST mode). Place the GF Cutout switch, located inside the control area of the main control cabinet, in the CUTOUT (down) position. Verify that all DC link voltage indicating lights are OFF. Connect a voltmeter across resistor R1 which is located in the power area of the main control cabinet. 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. Close the compartment door. Start the engine. Place the GF Cutout switch in the NORMAL (up) position. Apply the Load Brake, release the Parking Brake (propulsion system exits REST mode), and note that the voltmeter will momentarily read approximately 18 V and then drop to zero volts. 73
6. 7. 8. 9.
NOTE: If the voltmeter reading is significantly different from that stated above, remove voltage from the propulsion system. After verifying that voltage is removed from the propulsion system, check resistor R1 and its wiring, replace components and wiring as necessary, then repeat the above portion of the procedure before continuing.
10. Apply the Parking Brake (propulsion system commanded to REST mode). 11. Place the GF Cutout switch, located on the right hand side of the main control cabinet, in the CUTOUT (down) position. 12. Shut down the engine. 13. Verify that all DC link voltage indicating lights are OFF. 14. Disconnect and remove the voltmeter and secure the compartment door.
6.18.3.
Self Load Test Procedure
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, conduct the Self Load Test as follows: 1. 2. Verify that the Direction Selector switch is in the NEUTRAL position. Verify that the Parking Brake is ON (propulsion system commanded to REST mode).
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 without a wPTUt, skip the remainder of this procedure and follow the DID panel self load test procedure.
3. 4. 5. 6. 7. Close the PSC Real Time Data display screen by clicking on the X in the upper right corner of the screen. From the window browser, select PTU Screens > PSC > Normal_Operation > Tests > Self Load Engine Test (Fig. 38). The Self Load Engine Test screen is now displayed (Fig. 51). 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. Press on the accelerator pedal. Engine speed must be above 1200 RPM in 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 communicated to PSC.
8. Monitor the ENGLOAD value on the Self Load Engine Test screen during load testing. (This is a 0 to 10 V signal from the engine controller converted to a percentage value.) a. If the value is 50% during load testing, loading is optimal. b. If the value is below 50% during load testing, this is an indication of a weak engine and the propulsion system must decrease its load HP. c. If the value is above 50% during load testing, this is an indication of a strong engine and the propulsion system can increase its load HP. 74
FIG. 51. SELF LOAD ENGINE TEST SCREEN. E44394A.

9. When self load testing is complete, release the accelerator pedal and click on the EXIT LDBX button. Self load testing should stop.
10. Close the Self Load Engine Test display screen by clicking on the X in the upper right corner of the screen. 11. Click on the Target button to go back to the GE OHV wPTUt Toolbox Login screen, close the wPTUt Toolbox, shut down the PTU, and disconnect it from the PSC serial port.
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6.19. INVERTER LOAD TEST

WARNING: The inverter load test involves developing torque on the individual wheel motors at standstill. A location allowing for some movement of the truck is required. Personnel 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 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 and ensure the following in preparation for this test, correcting any problems before proceeding further: a. The braking system is functional. b. The wheel motors are clear for rotation and personnel are aware that wheels will be rotating one at a time. c. If tires are not installed, verify that the truck is solidly mounted on jack stands and that the truck is stable. 2. Connect the PTU to the PSC serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select PSC Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox . From the window browser, select PTU Screens > PSC > Normal_Operation > Real_Time > PSC Real Time Data (Fig. 38). The PSC Real Time Data screen is now displayed (Fig. 40). Place the following switches in the positions indicated: a. Parking Brake should be ON (propulsion system commanded to REST mode). b. Inverter #2 Cutout switch should be in the CUTOUT (down) position. c. Inverter #1 Cutout switch should be in the NORMAL (up) position. 6. 7. Start the engine. Release the Parking Brake (propulsion system exits REST mode).
3.
4. 5.
CAUTION: Do not accelerate the wheel motors if the truck is on jack stands.
8. Place the Direction Selector switch in the FORWARD position and verify that the truck moves forward if wheels 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. Record the following readings on the PSC Real Time Data screen: a. Record the torque command and feedback values for Inverter #1 (TQCMD1 and TRQFB1 ). The minimum torque command should be around 750 ftlbs. Note any significant differences. b. Record both Inverter #1 (I1LV) and Inverter #2 (I2LV) link voltages. They should be approximately the same with a maximum allowable difference of 7 V. The DC link volts should be approximately 700 V and the DC link amps should be less than 50 amps. 76
10. Place the Direction Selector switch in the NEUTRAL position. 11. Apply the Parking Brake (propulsion system commanded to REST mode).
NOTE: All LEDs, the Inverter #1 cutout switch and the Inverter #2 cutout switch are not present in the 17KG527B1 (or later) configuration of the 150 Ton AC control group.
12. Repeat steps 5 through 10 for Inverter #2 (with Inverter #2 Cutout switch in NORMAL position and Inverter #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. 13. Apply the Parking Brake (propulsion system commanded to REST mode), move both Inverter Cutout switches to the NORMAL (up) position, then release the Parking Brake (propulsion system exits REST mode). 14. If wheels and tires are installed, verify that truck moves forward in a smooth manner. Stop the truck and move Direction Selector switch to REVERSE. Again verify that truck moves in reverse in a smooth manner. If wheels and/or tires are not installed, verify that the wheel motors rotate in an even manner and that the following wheel motor rotations as viewed from the transmission side are correct: a. Direction Selector switch in FORWARD (1) Left wheel motor counter clockwise rotation (2) Right wheel motor clockwise rotation b. Direction Selector switch in REVERSE (1) Left wheel motor clockwise rotation (2) Right wheel motor counter clockwise rotation
NOTE: If problems are encountered during this testing, check the wheel 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.
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6.20. FUNCTIONAL GROUND FAULT DETECTION TEST

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 for ground fault detection checking, always ensure that the truck is shut down, the engine is stopped, the Parking Brake is ON (propulsion system commanded to REST mode), and ALL DC link voltage indicating lights are 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 as well before proceeding with maintenance or trouble shooting. Failure to do so may result in personnel injury or death.
If, for any reason, this test encounters ground fault detection problems (fails to detect entered fault), immediately stop any further testing and correct the problem. Each time a ground fault is detected, a ground fault event is 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. 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. 2. Positive DC link bus Negative DC link bus
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7. STATISTICAL DATA
7.1.
GENERAL DESCRIPTION AND DEFINITION
The Statistical Data Collector uses Parameter Counters and Parameter Profiles to record operating conditions 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 identification number called Par #, and a short name called Description . Each parameter is an occurrence that is 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 (TABLE 4, Statistical Data Codes Profiles, 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 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 Counter parameter, 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 intended 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 board when the user performed the reset. The second counter, Last Qtr is just the total number of counts for the parameter over the lastfiscalquarter, also known as the lastthreemonths. 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 thisquarter becomes lastquarter. 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. This counter has the same value in it all month long. At midnight on a month change, this counter is overwritten by the This Mnth value as thismonth becomes lastmonth. 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, Yesterday, keeps a moment by moment count of occurrences of the parameter over the previous day. This counter has the same value in it all day long. At midnight, this counter is overwritten by the This Day value as thisday becomes yesterday. 79
FIG. 52. TCI STAT_MENU SELECTIONS. E44371A.

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. Whenever the truck is programmed, that is, whenever the CPU Card has the contents of the flash proms changed, the LCount , Last Qtr, and This Qtr counts are not changed. However, the This Day count will be reset to zero.
7.2.
VIEW STATISTICAL COUNTERS
NOTE: It may be desirable to upload Statistical Counters to a PC for later viewing/analysis. Refer to Section 3.8., Consolidated Truck Data Save Function, for procedures.
The wPTUt provides the capability to view the current values of the statistical counters as follows: 1. 2. 3. 4. 5. 6. 7. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox . From the window browser, select PTU Screens > TCI > Special_tasks > Stat_Menu > View Counters (Fig. 52). The View Counters screen is now displayed (Fig. 53). Select the COUNTER Group to view from the menu on the screen, then click on View Counter Group. The Mine Counters screen displaying the selected COUNTER Group is now displayed (Fig. 54). Close the Mine Counters display screen by clicking on the X in the upper right corner of the screen. Select a different COUNTER Group if desired by repeating step 4 or close the View Counters screen by clicking on the X in the upper right corner of the screen.
80
8.
Click on the Target button to go back to the GE OHV wPTUt Toolbox Login screen, then close the wPTUt Toolbox, shut down the PTU, and disconnect it from the TCI serial port.
FIG. 53. VIEW COUNTERS SCREEN EXAMPLE. E45211.
FIG. 54. MINE COUNTERS SCREEN (PSC_STATS). E45212.
81
7.3.
VIEW STATISTICAL PROFILES
NOTE: It may be desirable to upload Statistical Profiles to a PC for later viewing/analysis. Refer to Section 3.8., Consolidated Truck Data Save Function, for procedures.
The wPTUt provides the capability to view the current values of the statistical profiles as follows: 1. 2. 3. 4. 5. 6. 7. 8. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox . From the window browser, select PTU Screens > TCI > Special_tasks > Stat_Menu > View Profiles (Fig. 52). The View Mine Profiles screen is now displayed (Fig. 55). Select the profile to view from the SELECT PROFILE TO VIEW menu on the screen, then click on VIEW PROFILES . The Mine Profiles screen displaying the selected profile is now displayed (Fig. 56). Close the Mine Profiles display screen by clicking on the X in the upper right corner of the screen. Select a different profile if desired by repeating step 4 or close the View Mine Profiles screen by clicking on the X in the upper right corner of the screen. Click on the Target button to go back to the GE OHV wPTUt Toolbox Login screen, then close the wPTUt Toolbox, shut down the PTU, and disconnect it from the TCI serial port.
FIG. 55. VIEW PROFILES SCREEN EXAMPLE. E45213.
82
FIG. 56. MINE PROFILES SCREEN (PSC_STATS). E45214.
83
7.4.
VIEW TRUCK STAT SERIAL REPORT
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.
The wPTUt Toolbox provides the capability to view the truck serial and configuration report as follows: 1. 2. 3. 4. 5. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox . From the window browser, select PTU Screens > TCI > Special_tasks > Stat_Menu > Stat Serial Report (Fig. 52). The Stat Serial Report screen displaying the Serial & Configuration Report is now displayed (Fig. 57). Close the Stat Serial Report display screen by clicking on the X in the upper right corner of the screen. Click on the Target button to go back to the GE OHV wPTUt Toolbox Login screen, then close the wPTUt Toolbox, shut down the PTU, and disconnect it from the TCI serial port.
7.5.
RESET STATISTICS
Provided that the user has the appropriate privilege level, the wPTUt Toolbox provides the capability to reset the propulsion system statistics as follows: 1. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox .
FIG. 57. STAT SERIAL REPORT SCREEN. E45219.
84
2. 3. 4.
From the window browser, select PTU Screens > TCI > Special_tasks > Stat_Menu > Reset Stats (Fig. 52). The Reset Stats screen displaying the Stat Reset Menu is now displayed (Fig. 58). Reset the desired stat (or stats) on the Reset Stats screen using the following methods: S S S 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 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 selection boxes and a question screen displays. Click on Yes to reset the selected statistics or No to leave the current statistics intact (Fig. 60).
S 5. 6.
Close the Reset Stats display screen by clicking on the X in the upper right corner of the screen. Click on the Target button to go back to the GE OHV wPTUt Toolbox Login screen, then close the wPTUt Toolbox, shut down the PTU, and disconnect it from the TCI serial port.
FIG. 58. RESET STATS SCREEN. E45220.
85
FIG. 59. STAT PROFILE MINE RESET SCREEN. E45221.
FIG. 60. RESET BOX QUESTION SELECTION SCREENS. E45223.
86
7.6.
UPLOAD STATISTICAL DATA TO A 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 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: 1. 2. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox . From the PTU Screens > TCI screen Menu Bar, select UpLoad > Consolidated Truck Data Save (Fig 14, refer to GEK91712).
NOTE: Files are normally uploaded to the following: c:/program files/geohvptu_xx/data_ac/<truck id date time>
3. 4. 5. Select the type of report to be saved from the Reports Type list, choose a Save Directory, then click on the Begin button to begin uploading (Fig. 15). Click on Close when the uploading is complete, then click on the Target button in the screen Tool Bar to go to the wPTUt startup screen. Close the wPTUt Toolbox, shut down the PTU, and disconnect it from the TCI serial port.
87
TABLE 3. STATISTICAL DATA CODES COUNTERS

Cntr. No. 301 Description Truck Life Units Hours Count Conditions The number of calendar hours that have elapsed since the CPU has been loaded with its current version of software. NOTE: This counter only has nonzero values in the Lifetime Counter column. The number of hours that the control power relay (CPR) has been energized. The number of hours of engine operation above the engine running threshold criteria. The number of hours when engine is idling and truck is stationary. The summation of the number of hours that the propulsion system has operated in propulsion, retard, ready and test. The number of hours that the Park Brake applied feedback is true while TCI is energized. The cumulative miles travelled by the truck. It is a calculated value, based upon the integrated average of the four wheelmotor speed signals. It is active when control power is on, and it is not sensitive to vehicle direction. The cumulative kilometers travelled by the truck. It is a calculated value, based upon the integrated average of the four wheelmotor speed signals. It is active when control power is on, and it is not sensitive to vehicle direction. The number of hours that wheel #1 was providing torque in either propulsion or retard, and was moving. The number of hours that wheel #2 was providing torque in either propulsion or retard, and was moving. The number of hours that the truck was moving forward in the propulsion mode of operation. The number of hours that the truck was moving forward in the retard mode of operation. The number of hours that the truck was moving in the propulsion mode of operation. The number of hours that the truck was moving in the retard mode of operation. The number of times when the Keyswitch was moved from the STOP to the ON position. The number of times that the GF contactor feedback has changed from deenergized to energized indication. The number of times that the GFR relay feedback has changed from deenergized to energized indication. The number of times that the RP1 contactor feedback has changed from deenergized to energized indication. The number of times that the RP2 contactor feedback has changed from deenergized to energized indication.
302 303 304 305 306 307
Control Power On Engine Operate Engine Idle Truck Operate Truck Parked Truck Travel
Hours Hours Hours Hours Hours Miles
308
Truck Travel
Kilometers
309 310 311 312 313 314 315 316 317 318 319
Wheel 1 Operate Wheel 2 Operate Propel Forward Retard Forward Propel Mode Retard Mode CPR Pickup GF Pickup GFR Pickup RP1 Pickup RP2 Pickup
Hours Hours Hours Hours Hours Hours Occurrences Occurrences Occurrences Occurrences Occurrences
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TABLE 3. STATISTICAL DATA CODES COUNTERS (Contd)

Cntr. No. 320 321 Description RP3 Pickup Dump Body Up Units Occurrences Occurrences Count Conditions The number of times that the RP3 contactor feedback has changed from deenergized to energized indication. 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. The number of times that the Full Payload input has changed from false to true. The number of times that the programmable speed set point #1 has been exceeded. The number of times that the programmable speed set point #2 has been exceeded. The number of times that the engine start request was actuated by the operators Keyswitch. The number of times that engine start request received while the engine above its running threshold criteria. The number of times that the control and cranking batteries were commanded to separate. The number of times that a crank command has been issued to the engine. The number of times that the measured engine speed has exceeded the engine running criteria. The number of times that the Engine Kill pushbutton was actuated. The number of times that the Park Brake switch was actuated. The number of times that the Park Brake pressure switch feedback transitioned from false to true, indicating that the Park Brake was applied. The number of times that the Direction Selector switch was moved to the Reverse position. The number of times that the Direction Selector switch was moved to the Forward position. The number of times that the Direction Selector switch was moved to command a change in direction while the truck was moving. The number of times that the Retard Speed Control switch was moved from Off to On. The number of times that the rest request was received by actuation of the Rest Request switch. The number of times that the override command was received by actuation of the Override switch. The number of times that the lamp test request was received by actuation of the Lamp Test switch. 89
322 323 324 325 326 327 328 329 330 331 332
Loaded Truck Speed Set 1 Speed Set 2 Engine Start Switch Engine On & Start Separate Batteries Engine Crank Engine Starts Engine Off Park Brake Request Park Brake Applied
Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences
333 334 335
SS to Reverse SS to Forward SS When Moving
Occurrences Occurrences Occurrences
336 337 338 339
RSC Switch On Rest Request Override Switch Lamp Test Switch
Occurrences Occurrences Occurrences Occurrences

Cntr. No. 340 341 342 343 344 345 346 347 348 349 350 351 352 353 354 355 356 357 358 359 360 361 362 363 364 Description Engine Cautions Engine OEM Overspeed Load Brake Load Brake Service Brake at Speed Service Brake at Speed Aux Shutdowns Starter Failure Coasting Rest Test Enter READY Enter Test Enter Propel Enter Retard Speed Control Active M1 Spin Time M1 Slide Time M2 Spin Time M2 Slide Time M1 Spin Count M1 Slide Count M2 Spin Count M2 Slide Count Service Brake Time Units Occurrences Occurrences Occurrences Seconds Occurrences Seconds Occurrences Occurrences Hours Hours Hours Occurrences Occurrences Occurrences Occurrences Occurrences Seconds Seconds Seconds Seconds Occurrences Occurrences Occurrences Occurrences Seconds Count Conditions The number of times that the Engine Cautions signal from the Engine Controller transitioned from low to high. The number of times that the Engine Speed increases above an OEMsettable limit. (150 Ton) The number of times that the Load Brake input transitioned from low to high. The amount of time that the Load Brake is applied. The number of times that the Service Brake is applied at speed. The amount of time that the Service Brake is applied at speed. The number of times that the aux_shutdown signal transitioned from low to high. The number of times the engine_starter_fail_di24 input transitions to true. The number of hours that are spent coasting. Ready mode is active and Wheel #1 or Wheel #2 speed is above 50 rpm. The number of hours that are spent in the Rest mode. Rest mode is active. The number of hours that are spent in the Test mode. Test mode is active. The number of times that the READY mode has been entered. The number of times that the Test mode has been entered. The number of times that the Propel mode has been entered. The number of times that the Retard mode has been entered. The number of times that propel torque is regulated in the speed limit mode. The number of seconds that Wheel #1 Spin Control is active. The number of seconds that Wheel #1 Slide Control is active. The number of seconds that Wheel #2 Spin Control is active. The number of seconds that Wheel #2 Slide Control is active. The number of times that Wheel #1 Spin Control is activated. The number of times that Wheel #1 Slide Control is activated. The number of times that Wheel #2 Spin Control is activated. The number of times that Wheel #2 Slide Control is activated. The number of seconds that the wet brake is applied and truck speed is > no motion speed.
90

Cntr. No. 365 366 Description Service Brake App Load Box Mode Units Occurrences Seconds Count Conditions The number of times that the wet brake is applied and truck speed is > no motion speed. The number of seconds that the system is in load box mode.
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Cntr. No. Description Units Count Conditions
Note:
1000 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1019 1020 1021 1022 1023 1024 1025 1026 1027 1028 1029 92
Parameter Numbers 1000 through 1099 correspond to DID Panel PSC Events 000 through 099, respectively (shown on DID panel and wPTUt Toolbox).
spare spare Ground Fault Failed Diode Panel GFCO Not Reset Propulsion System Over Temp Both Inv Comms Failed spare DC Link Over Volt ALTF Over Amps spare Retard Lever Signal Retard Pedal Signal Mid V Failure Analog Sensor Faults Restrictive Analog Sensor Fault PSC CPU Card Fault FB104 Digital Card FB143 Analog Card Riding Retard Pedal High Torque Limit TCI Comm Fault Persistent TCI Comm Fault Tertiary Overcurrent CFG File Error Blower Fault Cap Overpressure Panel Not Connected at Power Up spare spare Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences Occurrences Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS

Cntr. No. 1030 1031 1032 1033 1034 1035 1036 1037 1038 1039 1040 1041 1042 1043 1044 1045 1046 1047 1048 1049 1050 1051 1052 1053 1054 1055 1056 1057 1058 1059 1060 1061 1062 1063 1064 Description GF Contactor RP Contactors RPHP Balance spare ESS Input Grid Blower Computer Power Supply spare spare 24V Positive Bad 24V Negative Bad Self Load & Dir Battery Volt Low Battery Volt High Chopper Open Circuit Retard Circuit Short Engine Stall Shorted DC Link spare spare Tach Left Rear Tach Right Rear FLeft Speed Sig FRight Speed Sig Front Wheel Tachs Inverter SW Version spare spare spare spare Motor Over Speed spare Engine Load Sig spare 93 Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Units Occurrences Occurrences Occurrences Count Conditions See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS
Battery Boost Circuit Occurrences

Cntr. No. 1065 1066 1067 1068 1069 1070 1071 1072 1073 1074 1075 1076 1077 1078 1079 1080 1081 1082 1083 1084 1085 1086 1087 1088 1089 1090 1091 1092 1093 1094 1095 1096 Description Temp Input Bad spare spare spare spare Link Cap Level Getting Low Link Cap Level Too Low Ground Fault Circuit Problem Sensor Offset INV1 Comm Failed INV2 Comm Failed FB173 Card Inverter Failed VI Test Inv Bkgnd Msg spare spare spare spare spare CPS & Moving Aux Cooling Fault spare Engine HP Low HP Over Limit Engine Speed Command spare INV1 Cutout INV2 Cutout spare Limp Req Error BBRAM Error Unexpected System Reset Occurrences Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Units Occurrences Count Conditions See TABLE 5 EVENT CODE DESCRIPTIONS
94

Cntr. No. 1097 1098 1099 Description spare PTU Data Store Software Event Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Units Count Conditions
95

Note:
1100 1101 1102 1103 1104 1105 1106 1107 1108 1109 1110 1111 1112 1113 1114 1115 1116 1117 1118 1119 1120 1121 1122 1123 1124 1125 1126 1127 1128 1129 1130 1131 1132 1133 96
Parameter Numbers 1100 through 1199 correspond to Inverter #1 Event Codes 100 through 199, respectively (shown on DID panel and wPTUt Toolbox).
INV1 CPU Card INV1 CPU NR INV1 I/O Card INV1 I/O NR INV1 FO Card INV1 PS Card INV1 DC Power GDPS1 Fail spare INV1 LinkV Fail spare INV1 Input Volt Sen- Occurrences sor spare INV1 General INV1 General NR INV1 System INV1 A Phase INV1 A+ Phase INV1 A+ Phase NR INV1 A Phase INV1 A Phase NR spare INV1 A Phase Volts spare INV1 B Phase INV1 B+ Phase INV1 B+ Phase NR INV1 B Phase INV1 B Phase NR spare INV1 B Phase Volts spare Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences Occurrences Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS
INV1 A Phase Amps Occurrences
INV1 B Phase Amps Occurrences

Cntr. No. 1134 1135 1136 1137 1138 1139 1140 1141 1142 1143 1144 1145 1146 1147 1148 1149 1150 1151 1152 1153 1154 1155 Description INV1 C Phase INV1 C+ Phase INV1 C+ Phase NR INV1 C Phase INV1 C Phase NR spare spare INV1 C Phase Volts spare INV1 Tach 1 INV1 Tach 1 NR INV1 Tach 2 INV1 Tach 2 NR spare Chopper 1 NR spare Chopper 2 NR INV1 Misc spare INV1 Motor INV1 Motor Faults NR INV1 Second Load Occurrences Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS Units Occurrences Occurrences Occurrences Occurrences Occurrences Count Conditions See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS
1156 thru spare 1199
97

Note:
1200 1201 1202 1203 1204 1205 1206 1207 1208 1209 1210 1211 1212 1213 1214 1215 1216 1217 1218 1219 1220 1221 1222 1223 1224 1225 1226 1227 1228 1229 1230 1231 1232 1233 98
Parameter Numbers 1200 through 1299 correspond to Inverter #2 Event Codes 200 through 299, respectively (shown on DID panel and wPTUt Toolbox).
INV2 CPU Card INV2 CPU NR INV2 I/O Card INV2 I/O NR INV2 FO Card INV2 PS Card INV2 DC Power GDPS2 Fail spare INV2 LinkV Fail spare INV2 Input Volt Sen- Occurrences sor spare INV2 General INV2 General NR INV2 System INV2 A Phase INV2 A+ Phase INV2 A+ Phase NR INV2 A Phase INV2 A Phase NR spare INV2 A Phase Volts spare INV2 B Phase INV2 B+ Phase INV2 B+ Phase NR INV2 B Phase INV2 B Phase NR spare INV2 B Phase Volts spare Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences Occurrences Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS
INV2 A Phase Amps Occurrences
INV2 B Phase Amps Occurrences

Cntr. No. 1234 1235 1236 1237 1238 1239 1240 1241 1242 1243 1244 1245 1246 1247 1248 1249 1250 1251 1252 1253 1254 1255 Description INV2 C Phase INV2 C+ Phase INV2 C+ Phase NR INV2 C Phase INV2 C Phase NR spare spare INV2 C Phase Volts spare INV2 Tach 1 INV2 Tach 1 NR INV2 Tach 2 INV2 Tach 2 NR spare Chopper 1 NR spare Chopper 2 NR INV2 Misc spare INV2 Motor INV2 Motor Faults NR INV2 Second Load Occurrences Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS Units Occurrences Occurrences Occurrences Occurrences Occurrences Count Conditions See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS
1256 thru spare 1299
99

Note:
1600 1601 1602 1603 1604 1605 1606 1607 1608 1609 1610 1611 1612 1613 1614 1615 1616 1617 1618 1619 1620 1621 1622 1623 1624 1625 1626 1627 1628 1629 1630 1631 1632 1633 100
Parameter Numbers 1600 through 1699 correspond to TCI Events 600 through 699, respectively (shown on DID panel and wPTUt Toolbox).
spare FB144 CPU Card FB104 Digital I/O FB160 Analog I/O PSC Comm Bad Aux Comm Fault spare 5V Positive Bad 15V Positive Bad 15V Negative Bad Pot Ref Bad spare spare Analog Input BSep Cont Fail spare Forin & Revin Eng Start Denied spare Engine Warning Eng Kill & Speed spare Park Brake Problem Hyd Brake Fluid Hot Body Up & Load Body Up & Speed spare Battery Volts Baro Press Signal Motor Blower Press Amb Temp Signal CFG File Error BBRAM Error Occurrences Occurrences Occurrences Occurrences Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences Occurrences Occurrences Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS
Load Brake & Speed Occurrences

Cntr. No. 1634 1635 1636 1637 1638 1639 1640 1641 1642 Description Overload Restrictive Overload NR Aux Inverter Faults spare Engine Crank Timeout Engine Start Request & Running Accel Pedal too Low Crank Override Occurrences Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS Units Occurrences Occurrences Occurrences Count Conditions See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS See TABLE 5 EVENT CODE DESCRIPTIONS
Accel Pedal too High Occurrences Occurrences Occurrences
1643 thru spare 1690 1691 1692 1693 1694 1695 1696 1697 1698 1699 spare spare spare spare spare Unexpected CPU Reset spare Data Store spare Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS Occurrences See TABLE 5 EVENT CODE DESCRIPTIONS
101
7.7.
PROFILE (HISTOGRAM) DEFINITIONS
The word histogram is used in the definitions of the various statistical profiles in 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. STATISTICAL DATA CODES PROFILES

Prof. No. Description 401 Alt HPNET In Count Conditions This is a histogram of alternator input horsepower. The sample time is 1.0 second. The clock starts whenever the truck is in the propel state. The histogram breaks the horsepower spectrum into 17 buckets, and displays the time that was spent in each bucket. The buckets are defined as follows: NUMBER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 402 Control Battery NET INPUT HORSEPOWER RANGE 450 and below 451 to 650 651 to 850 851 to 1050 1051 to 1250 1251 to 1450 1451 to 1650 1651 to 1850 1851 to 2050 2051 to 2150 2151 to 2250 2251 to 2350 2351 to 2450 2451 to 2550 2551 to 2650 2651 to 2750 2751 and above
This is a histogram of Control Battery Voltage. The sample time is 1 second. The clock will run whenever the control system is up. NUMBER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. VOLTAGE RANGE 12 and below >12 to 14 >14 to 16 >16 to 18 >18 to 20 >20 to 22 >22 to 24 >24 to 26 >26 to 27 >27 to 28 >28 to 29 >29 to 30 >30 to 32 >32 to 34 >34 to 36 >36 to 38 38 and above
102
TABLE 4. STATISTICAL DATA CODES PROFILES (Contd)

Prof. No. Description 403 Count Conditions Crank Battery (2700 This is a histogram of Crank Battery Voltage. The sample time is 1 second. HP and 3500 HP The clock will run whenever the control system is up. (Truck_type = 320 Ton Only) AC only.) NUMBER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 404 405 Spare Retard Mode HP This is a histogram of DC link HP while in the retard mode. The sample time is 1.0 second. The clock starts whenever the truck is in the retard mode. The histogram breaks the horsepower spectrum into 17 buckets, and displays the time that was spent in each bucket. The buckets are defined as follows: NUMBER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 406 Spare HORSEPOWER RANGE 800 and below 801 to 1200 1201 to 1600 1601 to 2000 2001 to 2400 2401 to 2800 2801 to 3200 3201 to 3600 3601 to 3800 3801 to 4000 4001 to 4200 4201 to 4400 4401 to 4600 4601 to 4800 4801 to 5000 5001 to 5200 5201 and above VOLTAGE RANGE 2 >2 to 4 >4 to 6 >6 to 8 >8 to 10 >10 to 12 >12 to 14 >14 to 16 >16 to 18 >18 to 20 >20 to 22 >22 to 24 >24 to 26 >26 to 28 >28 to 30 >30 to 32 >32
103

Prof. No. Description 407 Truck Spd MPH Count Conditions This is a histogram of truck speed in mph for all modes of operation. The clock starts whenever control power (CPR) is on. Sample time is every 1.0 second. The histogram breaks the MPH spectrum into 17 buckets, and displays the time that was spent in each bucket. The buckets are defined as follows: NUMBER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 408 Truck Spd KPH TRUCK SPEED RANGE (MPH) 2.0 and below 2.1 to 4.0 4.1 to 5.0 5.1 to 6.0 6.1 to 8.0 8.1 to 10.0 10.1 to 12.0 12.1 to 17.0 17.1 to 22.0 22.1 to 27.0 27.1 to 32.0 32.1 to 37.0 37.1 to 39.0 39.1 to 41.0 41.1 to 43.0 43.1 to 45.0 45.1 and above
This is a histogram of truck speed in kph for all modes of operation. The clock starts whenever control power (CPR) is on. Sample time is every 1.0 second. The histogram breaks the KPH spectrum into 17 buckets, and displays the time that was spent in each bucket. The buckets are defined as follows: NUMBER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. TRUCK SPEED RANGE (KPH) 3.0 and below 3.1 to 6.4 6.5 to 8.0 8.1 to 9.6 9.7 to 12.8 12.9 to 16.0 16.1 to 19.0 19.1 to 27.0 27.1 to 35.0 35.1 to 43.0 43.1 to 51.0 51.1 to 60.0 60.1 to 63.0 63.1 to 66.0 66.1 to 69.0 69.1 to 72.0 72.1 and above
104

Prof. No. Description 409 Motor 1 RPM Count Conditions This is a histogram of Motor #1 rpm for all modes of operation. The clock starts whenever control power (CPR) is on. Sample time is every 1.0 second. The histogram breaks the RPM spectrum into 17 buckets, and displays the time that was spent in each bucket. The buckets are defined as follows: NUMBER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 410 Motor 2 RPM MOTOR 1 SPEED RANGE (RPM) 70 and below 71 to 287 288 to 452 453 to 567 568 to 735 736 to 900 901 to 1050 1051 to 1200 1201 to 1500 1501 to 1800 1801 to 2100 2101 to 2400 2401 to 2700 2701 to 3000 3001 to 3150 3151 to 3300 3301 and above
This is a histogram of Motor #2 rpm for all modes of operation. The clock starts whenever control power (CPR) is on. Sample time is every 1.0 second. The histogram breaks the RPM spectrum into 17 buckets, and displays the time that was spent in each bucket. The buckets are defined as follows: NUMBER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. MOTOR 2 SPEED RANGE (RPM) 70 and below 71 to 287 288 to 452 453 to 567 568 to 735 736 to 900 901 to 1050 1051 to 1200 1201 to 1500 1501 to 1800 1801 to 2100 2101 to 2400 2401 to 2700 2701 to 3000 3001 to 3150 3151 to 3300 3301 and above
105

Prof. No. Description 411 Event 636 Subid Count Conditions This is a histogram of the number of times each Event 636, Aux Blower Failure, subID logs. Each time the aux controller sends a 636 subID the appropriate bucket is incremented by 1. (Truck_type = 320 Ton AC only.) The buckets are defined as follows: NUMBER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 412 Service Brakes subID 1 subID 2 subID 3 subID 4 subID 5 subID 6 subID 7 subID 8 subID 9 subID 10 subID 11 subID 12 subID 13 subID 14 subID 15
This is a histogram of the Service Brake applied input ( Wet or Dry brakes) being active. The clock starts whenever control power (CPR) is on. Sample time is every 1.0 seconds. The buckets are defined as follows: NUMBER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 2.0 or less 2.1 to 4.0 4.1 to 5.0 5.1 to 6.0 6.1 to 8.0 8.1 to 10.0 10.1 to 12.0 12.1 to 17.0 17.1 to 22.0 22.1 to 27.0 27.1 to 32.0 32.1 to 37.0 37.1 to 39.0 39.1 to 41.0 41.1 to 43.0 43.1 to 45.0 45.1 or greater
106

Prof. No. Description 413 Ambient Temp Low Count Conditions This is a histogram of ambient temperature. The clock starts whenever control 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 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 414 Ambient Temp High TEMPERATURE RANGE (DEGREE C) 40 and below 39 to 30 29 to 25 24 to 20 19 to 15 14 to 10 9 to 5 4 to 0 1 to 5 6 to 10 11 to 15 16 to 20 21 to 25 26 to 30 31 to 35 36 to 40 41 and above
This is a histogram of ambient temperature. The clock starts whenever control 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 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. TEMPERATURE RANGE (DEGREE C) 35 and below 36 to 37 38 to 39 40 to 41 42 to 43 44 to 45 46 to 47 48 to 49 50 to 51 52 to 53 54 to 55 56 to 57 58 to 59 60 to 61 62 to 63 64 to 65 66 and above
107

Prof. No. Description 415 Engine Speed Count Conditions This is a histogram of engine speed in rpm for all modes of operation. The clock starts whenever control power (CPR) is on. The sample time is every 1.0 seconds. The histogram breaks the rpm spectrum into 17 buckets, and displays the time spent in each bucket. The buckets are defined as follows: NUMBER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 416 Engine Cranking Command Active ENGINE SPEED RANGE (RPM) 750 and below 751 to 850 851 to 950 951 to 1050 1051 to 1150 1151 to 1250 1251 to 1350 1351 to 1450 1451 to 1550 1551 to 1650 1651 to 1750 1751 to 1850 1851 to 1950 1951 to 2050 2051 to 2150 2151 to 2250 2251 and above
This is a histogram of the time duration of active engine cranking commands for each attempted 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 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. ENGINE CRANKING COMMAND ACTIVE (SEC) 1 and below 2 to 4 5 to 6 7 to 8 9 to 10 11 to 15 16 to 20 21 to 25 26 to 30 31 to 40 41 to 50 51 to 60 61 to 70 71 to 80 81 to 90 91 to 100 101 and above
108

Prof. No. Description 417 Engine Cranking Intervals (in minutes) Count Conditions This is a histogram of the time interval in minutes between engine cranking attempts. The histogram breaks the time interval spectrum into 17 buckets, and displays the number of times each buckets time interval between engine cranking attempts was recorded. The buckets are defined as follows: NUMBER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 418 Accel Pedal % ENGINE CRANKING INTERVAL (MIN) 0.5 and below 1.0 to 2.0 2.1 to 3.0 3.1 to 4.0 4.1 to 5.0 5.1 to 6.0 6.1 to 7.0 7.1 to 8.0 8.1 to 9.0 9.1 to 10.0 10.1 to 11.0 11.1 to 12.0 12.1 to 13.0 13.1 to 14.0 14.1 to 15.0 15.1 to 20.0 20.1 and above
This is a histogram of the Accel Pedal percentage during Propel. The sample time is every 1.0 seconds. The buckets are defined as follows: NUMBER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 6 or less 6.1 to 12 12.1 to 18 18.1 to 24 24.1 to 30 30.1 to 36 36.1 to 42 42.1 to 48 48.1 to 54 54.1 to 60 60.1 to 66 66.1 to 72 72.1 to 78 78.1 to 84 84.1 to 90 90.1 to 96 96.1 or greater
109

Prof. No. Description 419 RSC Percentage Count Conditions This is a histogram of the Retard Speed Control Percentage The sample time is every 1.0 seconds. The buckets are defined as follows: NUMBER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 420 Pot Reference 6 or less 6.1 to 12 12.1 to 18 18.1 to 24 24.1 to 30 30.1 to 36 36.1 to 42 42.1 to 48 48.1 to 54 54.1 to 60 60.1 to 66 66.1 to 72 72.1 to 78 78.1 to 84 84.1 to 90 90.1 to 96 96.1 or greater
This is a histogram of the pot reference value. The sample time is every 1.0 seconds. The buckets are defined as follows: NUMBER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 5 or less >5 to 8 >8 to 8.5 >8.5 to 9 >9 to 9.5 >9.5 to 10 >10 to 10.5 >10.5 to 11 >11 to 11.5 >11.5 to 12 >12 to 12.5 >12.5 to 13 >13 to 13.5 >13.5 to 14 >14 to 14.5 >14.5 to 15 >15.1 or greater
110

Prof. No. Description 421 Speed Unloaded Count Conditions This is a histogram of the truck speed while the truck is unloaded The sample time is every 1.0 seconds. The buckets are defined as follows: NUMBER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 422 Speed Loaded 2.5 or less >2.5 to 5 >5 to 7.5 >7.5 to 10 >10 to 12.5 >12.5 to 15 >15 to 17.5 >17.5 to 20 >20 to 22.5 >22.5 to 25 >25 to 27.5 >27.5 to 30 >30 to 32.5 >32.5 to 35 >35 to 37.5 >37.5 to 40 40 or greater
This is a histogram of the truck speed while the truck is loaded The sample time is every 1.0 seconds. The buckets are defined as follows: NUMBER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 2.5 or less >2.5 to 5 >5 to 7.5 >7.5 to 10 >10 to 12.5 >12.5 to 15 >15 to 17.5 >17.5 to 20 >20 to 22.5 >22.5 to 25 >25 to 27.5 >27.5 to 30 >30 to 32.5 >32.5 to 35 >35 to 37.5 >37.5 to 40 40 or greater
111

Prof. No. Description 422 Speed Loaded Count Conditions This is a histogram of the truck speed while the truck is loaded The sample time is every 1.0 seconds. The buckets are defined as follows: NUMBER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 423 Hyd Brake Deg 2.5 or less >2.5 to 5 >5 to 7.5 >7.5 to 10 >10 to 12.5 >12.5 to 15 >15 to 17.5 >17.5 to 20 >20 to 22.5 >22.5 to 25 >25 to 27.5 >27.5 to 30 >30 to 32.5 >32.5 to 35 >35 to 37.5 >37.5 to 40 40 or greater
This is a histogram of Aux Blower Inverter temperature. The sample time is every 1.0 seconds. The clock will start whenever control power (CPR) is on. All temperatures are in degrees C. 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: (Truck_type = 320 Ton AC only.) NUMBER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. TEMPERATURE RANGE <20 >20 to 40 >40 to 50 >50 to 60 >60 to 70 >70 to 80 >80 to 90 >90 to 95 >95 to 100 >100 to 105 >105 to 110 >110 to 115 >115 to 120 >120 to 125 >125 to 130 >130 to 140 >140
112

Prof. No. Description 424 Baro Pressure Count Conditions This is a histogram of the Barometric Pressure, ai_03 in TCI. The sample time is every 1.0 seconds. The clock will start whenever control power (CPR) is on. All pressure is in pounds per square inch (PSI). The histogram breaks the pressure spectrum into 17 buckets, and displays the time that was spent in each bucket. The buckets are defined as follows: NUMBER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 425 Loadbox HP PRESSURE RANGE (PSI) < 7.5 >7.5 to 8.0 >8.0 to 8.5 >8.5 to 9.0 >9.0 to 9.5 >9.5 to 10.0 >10.0 to 10.5 >10.5 to 11.0 >11.0 to 11.5 >11.5 to 12.0 >12.0 to 12.5 >12.5 to 13.0 >13.0 to 13.5 >13.5 to 14.0 >14.0 to 14.5 >14.5 to 15.0 >15.0
This is a histogram of Loadbox Horsepower. The sample time is every 1.0 seconds. If the system is in loadbox mode, the Total Engine Horsepower (HP) is recorded. All values are in HP. The histogram breaks the HP spectrum into 17 buckets, and displays the time that was spent in each bucket. The buckets are defined as follows: NUMBER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. HP 100 >100 to 650 >650 to 850 >850 to 1050 >1050 to 1250 >1250 to 1450 >1450 to 1650 >1650 to 1850 >1850 to 2050 >2050 to 2250 >2250 to 2450 >2450 to 2650 >2650 to 2850 >2850 to 3250 >3250 to 3450 >3450 to 3650 >3650
113

Prof. No. Description 426 Motor 1 Hi RPM Count Conditions This is a histogram of the Motor 1 RPM. The sample time is every 1.0 seconds. All values are in RPM. The histogram breaks the RPM spectrum into 17 buckets, and displays the time that was spent in each bucket. The buckets are defined as follows: NUMBER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 427 Motor 2 Hi RPM RPM 3300 >3300 to 3400 >3400 to 3500 >3500 to 3600 >3600 to 3700 >3700 to 3800 >3800 to 3900 >3900 to 4000 >4000 to 4100 >4100 to 4200 >4200 to 4300 >4300 to 4400 >4400 to 4500 >4500 to 4600 >4600 to 4700 >4700 to 4800 >4800
This is a histogram of the Motor 2 RPM. The sample time is every 1.0 seconds. All values are in RPM. The histogram breaks the RPM spectrum into 17 buckets, and displays the time that was spent in each bucket. The buckets are defined as follows: NUMBER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. RPM 3300 >3300 to 3400 >3400 to 3500 >3500 to 3600 >3600 to 3700 >3700 to 3800 >3800 to 3900 >3900 to 4000 >4000 to 4100 >4100 to 4200 >4200 to 4300 >4300 to 4400 >4400 to 4500 >4500 to 4600 >4600 to 4700 >4700 to 4800 >4800
428 440
spare
114
8. DIAGNOSTIC 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 information, depending upon the DID panels mode of display. The function keys assume different functionality depending upon the DID panels 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 appropriate condition for the REST mode to be active. TEST The AC OHV propulsion system is in a selftest mode of operation. READY The AC OHV propulsion system is ready for powering. PROPEL The AC OHV propulsion system is powered up and the Direction Selector switch is either in FORWARD or REVERSE. RETARD The AC OHV propulsion system is powered up and retard effort is commanded either from the retard pedal or retard speed control.
2. 3. 4.
5.
MENU/MESSAGE LINE
MENU/MESSAGE LINE F1 SOFT KEYS F2 F3 F4 F5
SOFT KEYS SOFT KEY FUNCTIONS WILL BE DESCRIBED IN THE SECTION OF THIS PUBLICATION WHERE THEY ARE USED.
FIG. 61. DID PANEL IDENTIFICATION. E44469B.
115
FIG. 62. DID PANEL EXAMPLE NORMAL DISPLAY (NO FAULTS). E45315.
116
8.2.
FAULTS DISPLAY
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 panels Faults Display mode screen provide the user with the following capabilities: (Fig. 64) 1. 2. 3. 4. Function key F1 (Up) moves the display UP through the active fault list, thereby displaying detailed information regarding the fault of interest. Function key F2 (Down ) moves the display DOWN through the active fault list, thereby displaying detailed information regarding the fault of interest. Function key F3 (Return) returns the user to the previous display. Function key F4 (Reset) enables the user to subsequently perform fault reset functions as follows: (Fig. 65) a. Pressing function key F1 (Reset1) after having pressed function key F4 above will reset the currently displayed fault. b. Pressing function key F2 (RESET*) after having pressed function key F4 above will reset ALL the currently active faults.
FIG. 63. DID PANEL MESSAGE EXAMPLE FAULTS DISPLAY. E45316.
FIG. 64. DID PANEL MESSAGE EXAMPLE FAULTS DISPLAY FUNCTION KEYS. E45317.
117
FIG. 65. DID PANEL MESSAGE EXAMPLE FAULT RESET FUNCTION KEYS. E45318.
c. Pressing function key F5 (cancel) exits the user from the fault reset screen and returns the user to the faults display screen. 5. Function key F5 displays additional information regarding the currently displayed fault.
8.3.
TEST DISPLAY
When function key F4 (MENU) is pressed when the DID panels Normal mode display is active, the DID panels Test Display mode appears to the user (Fig. 66). The function keys in the DID panels Test Display mode provide the user with the test capabilities described
FIG. 66. DID PANEL MESSAGE EXAMPLE TEST DISPLAY FUNCTION KEYS. E45319.
118
FIG. 67. DID PANEL MESSAGE EXAMPLE LOAD BOX TEST FUNCTION KEYS. E45320.
FIG. 68. DID PANEL MESSAGE EXAMPLE LOAD BOX TEST DATA. E45321.
8.3.1. Self Load Testing

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. Pressing function key F2 (Enter) requests Load Box mode of operation (Fig. 67). Press F2 to enter the Loadbox mode. With the engine running and the accelerator pedal fully pressed, the engine net 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). Pressing function key F5 (Return) stops the Load Box Test and returns the user to the top level DID Test Display mode (Fig. 66).
2.
119
FIG. 69. DID PANEL MESSAGE EXAMPLE PSC SOFTWARE VERSION DATA. E45322.
8.3.2. Software Version Display

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. 2. 3. 4. 5. PSC software version (Fig. 69) Inverter #1 software version Inverter #2 software version TCI software version TCI base configuration version
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. Link Capacitance Testing

Pressing function key F3 (Cap Test) will invoke the Link Capacitance Test (Fig. 66). The results of the Link Capacitance Test are then automatically displayed (Fig. 70). Commands now available to the user are as follows: 1. 2. 3. Pressing function key F2 (Start) will start the Link Capacitance Test again. Pressing function key F5 (Return) will return the user to the top level DID panel Test Display mode (Fig. 66). Pressing function key F5 (Return) again will return the user to the DID panels Normal mode display screen (Fig. 62).
120
FIG. 70. DID PANEL MESSAGE EXAMPLE LINK CAPACITANCE TEST DATA. E45323.
FIG. 71. DID PANEL MESSAGE EXAMPLE OVERSPEED SETTING DATA. E45324.
8.3.4. Overspeed Setting

1. Pressing F4 (Over Speed) displays the Overspeed Settings that are loaded into the AC OHV propulsion system (Fig. 71). Pressing function key F5 (Return) will return the user to the top level DID panel Test Display mode (Fig. 66). Pressing function key F5 (Return) again will return the user to the DID panels Normal mode display screen (Fig. 62).
2. 3.
121
122
9. EVENT CODES
WARNING: Lethal Voltages may be present on some circuits. Always turn off and Safety 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 propulsion system, unless stated otherwise, the truck engine should be shutdown 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 operators cab (and the wPTUt Toolbox) consist of three (3) digits. The source of the event detection information is as follows: Event Number Range 000 through 099 100 through 199 200 through 299 600 through 699 Event Source PSC Propulsion System Controller Inverter #1 Inverter #2 TCI Truck Control Interface
9.2.
EVENT RESTRICTIONS
Each event has an assigned restriction which indicates the limitations, if any, placed on propulsion system operation when that event is active. A brief description of each event restriction follows: Restriction NO PROPEL / LOADBOX Description No Propel (red) light is illuminated in the operator cab. No propulsion effort is allowed. Retard effort and DC link energization is allowed. Load Box mode is restricted. No Retard (red) light is illuminated in the operator cab. No propulsion effort or retard effort is allowed. The DC link is deenergized. 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. Inverter/wheel motor #1 is disabled. Limited propulsion and retard effort is available. Inverter/wheel motor #2 is disabled. Limited propulsion and retard effort is available. The engine speed is raised and RP1 is closed in response to a potential Retard circuit problem. No restrictions are imposed; the event is logged for information purposes only.
NO POWER SPEED LIMIT / SYSWARN
INVERTER 1 DISABLE INVERTER 2 DISABLE ENGINE SPEED / RP SYSEVENT
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 ACCESS SEQUENCE. E45241.
9.3.
TROUBLESHOOTING INFORMATION
In the following tables, troubleshooting recommendations are 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 recommendations.
9.4.
EVENT DATA ACCESS
NOTE: The following 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: 1. 2. 3. Connect the wPTUt to the TCI serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox . From the window browser, select PTU Screens > TCI > Special_Tasks > Event_Menu (Fig. 72). The Event_Menu list of screens is now displayed. Doubleclick on the desired screen to display it.
124
FIG. 73. TCI EVENT SUMMARY SCREEN. E44368B.
9.4.1.
View TCI Event Summary Screen
Perform the following to view the TCI Event Summary screen. 1. 2. From the Event_Menu , doubleclick on TCI Event Summary to select that screen (Fig. 72). The TCI Event Summary screen is now displayed (Fig. 73). This screen contains the following information for each recorded event: a. The name and number for each event b. The subID for each event. (Events with only one subID will have 01 as their subID.) c. The time and date of the event occurrence d. The time and date of the reset of the event (If the event is not reset, this column will display all zeroes for the reset time and date.) 3. Close the TCI Event Summary display screen by clicking on the X in the upper right corner of the screen.
125
FIG. 74. TCI TRIGGER DATA SCREEN. E45242.
9.4.2.
View TCI Trigger Data Screen
Perform the following to view the TCI Trigger Data screen. 1. 2. From the Event_Menu , doubleclick on TCI Trigger Data to select that screen (Fig. 72). The TCI Trigger Data screen is now displayed (Fig. 74). The TCI Trigger Data screen is a real time screen, similar to Figure 46. It captures the propulsion 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 DATA PACKS SCREEN. E44369B.
9.4.3.
View TCI 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 are a limited number of available data packs, and not every event will trigger the recording of a data pack. Typically, the recurrence of an event that already has a data pack that has NOT been reset, will NOT trigger the creation of another data pack. Perform the following to view the TCI Data Packs screen. 1. 2. From the Event_Menu , doubleclick on TCI Data Packs to select that screen (Fig. 72). The TCI Data Packs screen is now displayed (Fig. 75). This screen contains the following information for each data pack: a. The data pack number b. The associated event number and subID for the data pack number c. The time and date when the data pack was created d. The time and date of the data pack reset (If the data pack is reset, it is enabled to be overwritten by the next event that would trigger a data pack.) 3. Close the 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. E45244.
9.5.
RESET TCI EVENTS SCREEN
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. 2. 3. From the Event_Menu , doubleclick on Reset TCI Events to select that screen (Fig. 72). The Reset TCI Events screen is now displayed (Fig. 76). The user will then be asked if all active TCI events are to be reset. Click on Yes to reset all active TCI events or No to abort this action. The screen automatically closes upon either selection.
NOTE: When events are reset, their data packs are enabled to be overwritten by subsequent events. Reset events remain in the event summary list until they are erased, however.
128
FIG. 77. ERASE TCI EVENTS SCREEN. E45245.
9.6.
ERASE TCI EVENTS SCREEN
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. 2. 3. From the Event_Menu , doubleclick on Erase TCI Events to select that screen (Fig. 72). The Erase TCI Events screen is now displayed (Fig. 77). The user will then be asked if all stored TCI events are to be erased. Click 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.
EVENT AND INVERTER PARAMETERS LIST
A short description of all TCI events, PSC events, and inverter events is provided on the Events & Inv Params screen. This screen lists all the events in numerical order and provides a brief description of the 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: 1. Connect the wPTUt to the TCI or PSC serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select PSC Panel or TCI Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox . From the window browser, select PTU Screens > TCI or PSC > Special_Tasks > Events & Inv Params (Fig. 72). The Events & Inv Params screen is now displayed (Fig. 78). Click on the desired event list button (PSC Event List, TCI Event List, Inverter Event List) to open. (Use the scroll bar on the side to navigate through the list). Close the list by clicking on the X in the upper right corner of the screen. Close the Events & Inv Params display screen by clicking on the X in the upper right corner of the screen. Click on the Target button to go back to the GE OHV wPTUt Toolbox Login screen, close the wPTUt Toolbox, shut down the PTU, and disconnect it from the serial port. 129
2. 3. 4. 5. 6. 7.
FIG. 78. EVENTS & INV PARAMS SCREEN. E44370A.
130
TABLE 5. EVENT CODE DESCRIPTIONS AND INFORMATION

Event Description Event Restrictions (If Any) Detection Information
NOTE: Not all faults are present on all propulsion systems. Certain faults apply to specific propulsion systems only and will only be detected on those propulsion systems.
000No Fault 002High Ground Fault None NO POWER No faults present. 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 Failed diode in main rectifier detected. Generator Field CutOut switch (GFCO) moved to cutout position while propulsion system not in REST Mode (link is energized). A component of the propulsion system, identified by the following subID, exceeded its operational temperature limit: :01Auxiliary Blower Control Phase Control Rectifier (AUXPC) :02Auxiliary Blower Control Inverter (AUXINV) :03Alternator Field Static Exciter (AFSE) :04Alternator :05Left Wheel motor Stator :06Left Wheel motor Rotor :07Right Wheel motor Stator :08Right Wheel motor Rotor :09Chopper Module GTO :10Chopper Module Diode :11Left Wheel motor Inverter GTO :12Left Wheel motor Inverter Diode :13Right Wheel motor Inverter GTO :14Right Wheel motor Inverter Diode :15Rectifier Diode 006Both INV Comms Failed 008DC Link Overvoltage NO POWER NO POWER PSC lost communication with both inverters. DC link exceeded a voltage limit, identified by the following subID: :01Persistently above a level while not in retard operation :02Persistently above a level while in retard operation :03Instantaneously above a level regardless of operating mode 009Alt Field Overcurrent NO POWER Alternator field current exceeded a limit, identified by the following subID: :01Persistently above a level :02Instantaneously above a higher level :03With persistence due to low engine speed 011Retard Lever SYS EVENT The received signal from the Retard Lever exceeded a limit, as identified by the following subID: :01Signal volts too high :02Signal volts too low 012Retard Pedal Bad SYS EVENT The received signal from the Retard Pedal exceeded a limit, as identified by the following subID: :01Signal volts too high :02Signal volts too low 013Midvolt Test Failure NO POWER Inverter failed its midvoltage self test.
003Failed Diode 004GF Cutout Not Reset 005Drive System Overtemp
NO POWER SYS EVENT NO PROPEL
131
TABLE 5. EVENT CODE DESCRIPTIONS AND INFORMATION (Contd)

Event Description
014Analog Sensor Fault
Event Restrictions (If Any)

SPEED LIMIT
Detection Information
The received signal from a sensor, identified by the following subID, exceeded a limit: :01Alternator Field Current :03Loadbox Current (LDBX) :04Alternator 3Phase Voltage :05Alternator Field Volts :10PSC Link Voltage :11Inverter No. 1 Link Voltage :12Inverter No. 2 Link Voltage :13A2D Ground :14A2D Gain :15Fault Current :16ATOC :21DB Grid Blower No. 1 Current :22DB Grid Blower No. 2 Current
015Restrictive Analog Sensor Fault
NO POWER
The received signal from a sensor, identified by the following subID, exceeded a limit: :02Link Current
016PSC CPU Card
NO POWER
A problem occurred with a PSC CPU card task, as identified by the following subID: :01Task 1 failed to initialize :02Task 2 failed to initialize :03Task 3 failed to initialize :04Task 4 failed to initialize :05Task 5 failed to initialize :06Task 6 failed to initialize :07Maintenance task failed to initialize :09FLASH CRC computation did not match expected value :10BRAM CRC computation did not match expected value :11Tasks took too long to initialize :12BBRAM data pack pointers corrupted
017PSC Digital I/O Card Fault 018PSC Analog I/O Card Fault
NO POWER NO POWER
PSC CPU lost communication with the FB104 PSC digital I/O card. PSC CPU lost communication with the FB143 PSC analog I/O card, as further identified by the following subID: :01PSC Analog I/O card missing :02PSC Analog I/O communication timed out
019Riding Retard Pedal 020High Torque Timeout 021TCI Comm Fault
SYS EVENT NO PROPEL NO PROPEL
Brake and Propel Pedal signals simultaneously received and truck speed greater than 5 mph. Low speed torque limit exceeded. PSC lost or received corrupted communication from TCI, as further identified by the following subID: :01Message Missing :02Bad Tick :03Bad CRC :04Overflow :05Bad Start :06Bad Stop
132

Event Description
022Persistent TCI Comm Fault 023Tertiary Overcurrent 024PSC Config File

NO POWER NO POWER NO POWER
PSC detected persistent lost or corrupted communication from TCI over a period of time with truck stopped. Alternator field tertiary current limit exceeded. Incorrect or missing PSC configuration file detected, as further identified by the following subID: :01Configuration file not loaded :02Configuration file CRC computation failed :03Configuration file has incorrect major release number :04Overspeed values in configuration file are incorrectly set.
025Aux Blower System
NO POWER
Problem with the auxiliary blower control system detected, as further identified by the following subID: :01Auxiliary blower control speed feedback indicates no or incorrect blower speed :02Frequent auxiliary blower control fault shutdowns
026Cap Overpressure
NO POWER
Filter capacitor overpressure failure detected, as further identified by the following subID: :01Inverter No. 1 filter cap overpressure :02Inverter No. 2 filter cap overpressure
027Panel Not Connected at Power Up
NO POWER
One of PSC panel connectors not connected properly. Further identified by the following subID: :01CNFB :02CNI/CNX (3500 HP, 150 Ton) :03Aux blower connector
030GF Contactor 031Battery Boost Circuit
SPEED LIMIT SPEED LIMIT
GF contactor command and feedback do not agree. GFR contactor failed to open or close when commanded. Further identified by the following subID: :01GFR failed to open :02GFR failed to close :03SCR3 failed
032RP Contactor
SPEED LIMIT & STUCK RP
RP1 contactor command and feedback do not agree. Further identified by the following subID: :01RP1 :02RP2 :03RP3
033Retard Circuit 035Engine Speed Sensor 036GY19 Grid Blower
SPEED LIMIT & STUCK RP SPEED LIMIT NO POWER Engine speed signal exceeded upper or lower limit. Grid blower failure detected, further identified by the following sub ID: :01Grid blower no. 1 stalled :02Grid blower no. 2 stalled :03Grid blower no. 1 open :04Grid blower no. 2 open :05Excessive difference between grid blower motor currents
133

Event Description
037Computer Power Supply

SPEED LIMIT
Computer Power Supply voltages exceeded upper or lower limit, further identified by the following subID: :015 V DC positive :0215 V DC positive :0315 V DC negative
040Volts 24 Positive 041Volts 24 Negative 042Direction Requested During Selfload 043Propulsion Battery Voltage Low 044Propulsion Battery Voltage High 045Chopper Open Circuit
SPEED LIMIT SPEED LIMIT NO PROPEL
+24V Power Supply exceeded upper or lower limit. 24V Power Supply exceeded upper or lower limit. Forward or Reverse Switch command received while in Selfload Mode of operation. Propulsion system battery voltage below low limit. Propulsion system battery voltage above high limit. Chopper Module failed during chopper self test, further identified by the following subID: :01Chopper 1 :02Chopper 2
SPEED LIMIT SYS EVENT SPEED LIMIT
046Retard Short Circuit 047Engine Stall 048Shorted DC Link During Startup 051Tach Left Rear
SPEED LIMIT & ENGINE SPD NO POWER NO POWER INV1 DISABLE
Failure during chopper self test. Link voltage decayed too quickly when AFSE command set low, prior to starting test. Engine stall condition detected. System detected a potential short on the DC link while attempting to charge link. Problem occurred with tach on left rear wheelmotor, further defined by the following subID: :01Tach signal indicating zero wheel movement when others are indicating movement :02Tach signal indicating wheel movement when others are indicating zero movement
052Tach Right Rear
INV2 DISABLE
Problem occurred with tach on right rear wheelmotor, further defined by the following subID: :01Tach signal indicating zero wheel movement when others are indicating movement :02Tach signal indicating wheel movement when others are indicating zero movement
053Tach Left Front
SYS EVENT
Problem occurred with tach on left front wheelmotor, further defined by the following subID: :01Tach signal indicating zero wheel movement when others are indicating movement :02Tach signal indicating wheel movement when others are indicating zero movement
134

Event Description
054Tach Right Front

SYS EVENT
Problem occurred with tach on right front wheelmotor, further defined by the following subID: :01Tach signal indicating zero wheel movement when others are indicating movement :02Tach signal indicating wheel movement when others are indicating zero movement
055Front Wheel Tachs 056Inverter Software Version
SYS EVENT SYS EVENT
Problem occurred with tachs on front wheel motors. Incorrect version of Inverter Software is installed. Further identified by the following subID: :01Inverter #1 :02Inverter #2
061Motor Overspeed 063Engine Load Signal Fault
SYS EVENT SYS EVENT
Truck exceeded motor overspeed limit. The Engine Load Signal feedback from the engine controller is outside of limit, further defined by the following subID: :01Below minimum value :02Above maximum value :03PWM signal failed low :04PWM signal failed high :05PWM signal failed incorrect period
065Analog Input Range Check
SPEED LIMIT (10 MPH)
Analog input outside its design range, further identified by the following subID: :01Auxiliary blower control phase controller temperature :02Auxiliary blower control inverter temperature :03Alternator field static exciter temperature :04Alternator temperature :05Left rear wheelmotor stator temperature :06Left rear wheelmotor rotor temperature :07Right rear wheelmotor stator temperature :08Right rear wheelmotor rotor temperature :09Chopper module GTO temperature :10Chopper module diode temperature :11Left rear wheelmotor inverter GTO temperature :12Left rear wheelmotor inverter diode temperature :13Right rear wheelmotor inverter GTO temperature :14Right rear wheelmotor inverter diode temperature :15Rectifier diode temperature
070Link Capacitance Low Caution
SYS EVENT
Link capacitance low, but acceptable for operation. NOTE: Nominal for 17KG498D2 and newer control: 21600 uF Nominal for 17KG498D1 and earlier control: 24000 uF Event declared when measurement below: 15000 uF Nominal for 17KG527 control: 13500 uF Event declared when measurement below: 7875 uF (527 group)
135

Event Description
071Link Capacitance Low Warning

Link capacitance below acceptable limit for normal operation. NOTE: Nominal for 17KG498D2 and newer control: 21600 uF Nominal for 17KG498D1 and earlier control: 24000 uF Event declared when measurement below: 12500 uF Nominal for 17KG527 control: 13500 uF Event declared when measurement below: 7875 uF (527 group)
072Ground Circuit
Problem detected with ground fault detection circuit which is typically associated with failure of the filter capacitor test to discharge the capacitors within 30 seconds. Communication attempt with Inverter #1 timed out. Inverter 1 not cutout. Further identified by the following subID: :01No communication Inverter #1 :02Inverter #1 customer option bit
074Inverter1 Comm Failed
INV1 DISABLE
075Inverter 2 Comm Failed
INV2 DISABLE
Communication attempt with Inverter #2 timed out. Inverter 2 not cutout. Further identified by the following subID: :01No communication Inverter #2 :02Inverter #2 customer option bit
076FB173 Card
NO POWER
A failure in the FB173 card was detected, further identified by the following subID: :01Speed FPGA did not download correctly :02Speed count update not changing :03Alternator FPGA did not download correctly :04Microcontroller SRAM did not program :05Slow task counter is less than minimum value :06Medium task counter is less than minimum value :07Fast task timer is less than minimum value :08FD task timer is less than minimum value :09Link current value is out of limits :10Alternator FPGA timed out
077Inverter Failed VI Test
NO POWER
Inverter 1 or Inverter 2 failed during VI test. System forced to link 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. A failure in the inverter background communication was detected. Further identified by the following subID: :01Inverter #1 :02Inverter #2
078Inverter Background SYS EVENT Communication Failure
084Control Power Switch 085Auxiliary Cooling Fault
SYS EVENT
Loss of control power switch feedback while truck moving.
SYS EVENT
Problem detected with auxiliary blower control system, further identified by the following subID: :02Auxiliary blower motor speed signal out of range :03Excessive difference between auxiliary blower motor speed feedback and auxiliary blower motor speed command :04Abnormal shutdown of auxiliary blower control system
136

Event Description
087HP Low 088HP Limit

SYS EVENT SYS EVENT
Propulsion system adjusted HP load on engine has been reduced to its minimum value for an excessive period of time. Excessive propulsion system demand on available engine HP, further identified by the following subID: :01Propulsion system HP demand in propel mode exceeds available engine HP for a persistent period of time :02Propulsion system HP demand in propel or ready mode could result in engine stall
089Engine Speed Command
SYS EVENT
Engine speed does not match engine command, further identified by the following subID: :02Allowable difference between engine command and actual engine speed exceeded
091Inverter 1 cutout 092Inverter 2 cutout 094Illegal Limp Mode 095Bad BRAM Battery
SYS EVENT SYS EVENT SYS EVENT SYS EVENT
Inverter 1 is cutout. Inverter 2 is cutout. Limp Mode requested (i.e. inverter 1 or 2 cutout switch actuated) when truck is moving. BRAM battery voltage below acceptable limit. PSC CPU reset detected without reset request. PSC data store commanded via PTU.
096Unexpected System SYS EVENT Reset 098Data Store SYS EVENT
NOTE: Faults 100 199 as shown in this table apply to Inverter #1. The same 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 and Fault 200 is an Inverter #2 CPU Card Restrictive fault.
100Inverter 1/2 CPU Card Restrictive 101Inverter 1/2 CPU Card NonRestrictive 102Inverter 1/2 I/O Card Restrictive 103Inverter 1/2 CPU Card NonRestrictive 104Inverter 1/2 Fiber Optic Card 105Inverter 1/2 Power Supply Card 106Inverter 1/2 DC Power Wiring INV 1/2 OFF SPEED LIMIT (10 MPH) INV 1/2 OFF SPEED LIMIT (10 MPH) INV 1/2 OFF SPEED LIMIT (10 MPH) SYS EVENT Restrictive Inverter 1/2 CPU card problem detected. NonRestrictive Inverter 1/2 CPU card problem detected.
Restrictive Inverter 1/2 I/O card problem detected. NonRestrictive Inverter 1/2 I/O card problem detected.
INV 1/2 OFF SPEED LIMIT (10 MPH) INV 1/2 OFF SPEED LIMIT (10 MPH) INV 1/2 OFF SPEED LIMIT (10 MPH)
Inverter 1/2 fiber optic card problem detected. Inverter 1/2 power supply card problem detected. DC power wiring problem detected, further defined by the following subID: :01DC power connection open :02Link and phase voltage mismatch
107Inverter 1/2 Gate Drive Power Supply 109Inverter 1/2 Link Voltage Sensor
SYS EVENT INV 1/2 OFF SPEED LIMIT (10 MPH)
Inverter 1/2 gate drive power supply problem detected. Inverter 1/2 link voltage sensor problem detected.
137

Event Description Event Restrictions (If Any) Detection Information
Inverter 1/2 input filter voltage sensor problem detected. Inverter 1/2 phase current or voltage unbalance or exceeded limit detected. Inverter 1/2 electrical noise detected on signal channels or operational voltage limits exceeded. Inverter#1/System Controller interface problem detected such as inconsistent commands, loss of communication, or sensor signals beyond limits. Inverter#1 Phase A problem detected such as GTO failure to follow command or Phase A overcurrent. Restrictive Inverter#1 Phase A Positive (+) problem detected such as module failure to follow command. NonRestrictive Inverter#1 Phase A Positive (+) problem detected.
111Inverter 1/2 Input INV 1/2 OFF SPEED Filter Voltage Sensor LIMIT (10 MPH) 113General Inverter 1/2 Restrictive 114General Inverter 1/2 NonRestrictive 115Inverter 1/2/System Controller Interface INV 1/2 OFF SPEED LIMIT (10 MPH) SYS EVENT INV 1/2 OFF SPEED LIMIT (10 MPH)
116Inverter 1/2 Phase A INV 1/2 OFF SPEED LIMIT (10 MPH) 117Inverter 1/2 Phase A INV 1/2 OFF SPEED Positive (+) LIMIT (10 MPH) Restrictive 118Inverter 1/2 Phase A SYS EVENT Positive (+) NonRestrictive 119Inverter 1/2 Phase A INV 1/2 OFF SPEED Negative () LIMIT (10 MPH) Restrictive 120Inverter 1/2 Phase A Negative () NonRestrictive 121Inverter 1/2 Phase A Current 123Inverter 1/2 Phase A Voltage 125Inverter 1/2 Phase B 126Inverter 1/2 Phase B Positive (+) Restrictive 127Inverter 1/2 Phase B Positive (+) NonRestrictive 128Inverter 1/2 Phase B Negative () Restrictive 129Inverter 1/2 Phase B Negative () NonRestrictive 130Inverter 1/2 Phase B Current 132Inverter 1/2 Phase B Voltage 134Inverter 1/2 Phase C SYS EVENT
Restrictive Inverter#1 Phase A Negative () problem detected such as module failure to follow command. NonRestrictive Inverter#1 Phase A Negative () problem detected.
INV 1/2 OFF SPEED LIMIT (10 MPH) INV 1/2 OFF SPEED LIMIT (10 MPH) INV 1/2 OFF SPEED LIMIT (10 MPH) INV 1/2 OFF SPEED LIMIT (10 MPH) SYS EVENT
Inverter#1 Phase A current sensor or Phase A current problem detected. Inverter#1 Phase A voltage sensor or Phase A voltage problem detected. Inverter#1 Phase B problem detected such as GTO failure to follow command or Phase B overcurrent. Restrictive Inverter#1 Phase B Positive (+) problem detected such as module failure to follow command. NonRestrictive Inverter#1 Phase B Positive (+) problem detected.
INV 1/2 OFF SPEED LIMIT (10 MPH) SYS EVENT
Restrictive Inverter#1 Phase B Negative () problem detected such as module failure to follow command. NonRestrictive Inverter#1 Phase B Negative () problem detected.
INV 1/2 OFF SPEED LIMIT (10 MPH) INV 1/2 OFF SPEED LIMIT (10 MPH) INV 1/2 OFF SPEED LIMIT (10 MPH)
Inverter#1 Phase B current sensor or Phase B current problem detected. Inverter#1 Phase B voltage sensor or Phase B voltage problem detected. Inverter#1 Phase C problem detected such as GTO failure to follow command or Phase C overcurrent.
138

Event Description
135Inverter 1/2 Phase C Positive (+) Restrictive 136Inverter 1/2 Phase C Positive (+) NonRestrictive 137Inverter 1/2 Phase C Negative () Restrictive 138Inverter 1/2 Phase C Negative () NonRestrictive 141Inverter 1/2 Phase C Voltage 143Inverter 1/2 Tach 1 Restrictive 144Inverter 1/2 Tach 1 NonRestrictive 145Inverter 1/2 Tach 2 Restrictive 146Inverter 1/2 Tach 2 NonRestrictive 148Inverter 1/2 Chopper 1 150Inverter 1/2 Chopper 2 151Inverter 1/2 Tach Differential 153Inverter 1/2 Motor Restrictive

Restrictive Inverter#1 Phase C Positive (+) problem detected such as module failure to follow command. NonRestrictive Inverter#1 Phase C Positive (+) problem detected.
Restrictive Inverter#1 Phase C Negative () problem detected such as module failure to follow command. NonRestrictive Inverter#1 Phase C Negative () problem detected.
INV 1/2 OFF SPEED LIMIT (10 MPH) INV 1/2 OFF SPEED LIMIT (10 MPH) SYS EVENT SYS EVENT SYS EVENT INV 1/2 OFF SPEED LIMIT (10 MPH) INV 1/2 OFF SPEED LIMIT (10 MPH) INV 1/2 OFF SPEED LIMIT (10 MPH) INV 1/2 OFF SPEED LIMIT (10 MPH)
Inverter#1 Phase C voltage sensor or Phase C voltage problem detected. Restrictive Inverter#1 Tach 1 signal problem detected. NonRestrictive Inverter#1 Tach 1 signal problem detected. Restrictive Inverter#1 Tach 2 signal problem detected. NonRestrictive Inverter#1 Tach 2 signal problem detected. Inverter#1 Chopper 1 operational problem detected. Inverter#1 Chopper 2 operational problem detected. Excessive difference between Inverter 1/2 Tachs 1 and 2. Inverter 1/2 detected a motor connection problem further defined by the following subID: :01Motor connection open :02Motor connection short
154Inverter 1/2 Motor NonRestrictive
SYS EVENT
Inverter 1/2 detected a motor temperature exceeding its limit further defined by the following subID: :01Motor rotor temperature high :02Motor stator temperature high
155Second Load Connection Open
SYS EVENT
Inverter 1/2 detected a second open load connection.
139

Event Description
601TCI CPU Card FB144

NO PROPEL
A problem was detected with the TCI CPU card, further identified by the following subID: :0110 msec task failed to initialize :0220 msec task failed to initialize :0350 msec task failed to initialize :04100 msec task failed to initialize :05200 msec task failed to initialize :0650 msec fault manager task failed to initialize :07Flash CRC computation did not match expected value :09Maintenance task failed to initialize :10Upon powerup, excessive bus time outs occurred :11Upon powerup, the status of key memory data in BBRAM was found to be invalid :12CRC on protected areas of BBRAM did not match expected value
602FB104 TCI Digital I/O Card 603FB160 TCI Analog I/O Card 604TCI to PSC RS422 Comm
NO PROPEL NO PROPEL SPEED LIMIT (10 MPH)
A problem was detected with the TCI digital I/O card. A problem was detected with the TCI analog I/O card. Serial link communication with PSC was lost for a persistent time period, further identified by the following subID: :01Missing message :02Bad tick :03Bad CRC :04FIFO overflow :05Bad start bit :06Bad stop bit
605Aux Comm Fault 607Positive 5 volts 608Positive 15 Volts 609Negative 15 Volts 610Pot Reference 613Analog Input
None SPEED LIMIT (10 MPH) SPEED LIMIT (10 MPH) SPEED LIMIT (10 MPH) SPEED LIMIT (10 MPH) SPEED LIMIT (10 MPH)
Serial link communication with the Auxiliary Blower Control System was lost for a persistent time period. +5V Power Supply exceeded limits for a persistent period of time. +15V Power Supply exceeded limits. 15V Power Supply exceeded limits. Pot Reference exceeded limits. An analog signal input on the analog I/O card exceeded its limits for a persistent period of time, as defined by the following subID: :01Ground (A2D) :02Gain Check (A2D)
614Battery Separate Contactor
SYS EVENT
The battery separate contactor failed to operate in an expected manner as further defined by the following subID: :01Battery separate failure :02Crank battery > control battery :03Control battery > crank battery
616Simultaneous Forward and Reverse Command
NO PROPEL
Simultaneous receipt of forward and reverse direction commands.
140

Event Description
617Engine Start Request Denied

SYS EVENT
The engine start request was denied for the following reason defined by the subID: :01Engine warning signal received during cranking :02Engine Kill signal received during cranking
619Engine Warning 620Engine Kill while Moving 622Park Brake
NO PROPEL NO PROPEL NO PROPEL
The engine warning signal was received when the engine speed is above the run threshold. The engine kill signal was received while the truck was moving. Unexpected park brake operation defined by the following subID: :01Park brake command and feedback do not agree :02Park brake set feedback received while truck moving
623Hydraulic Brake
SYS EVENT
The hydraulic brake fluid temperature signal exceeded its maximum limit, further defined by the following subID: :01Tank :02 Left Front Outlet :03 Right Front Outlet :04 Left Rear Outlet :05 Right Rear Outlet
624Body Up and Payload Indication 625Extended Battery Reconnect Time 628Connected Batteries
SPEED LIMIT (10 MPH) None SYS EVENT
Simultaneous receipt of both full payload and body up signals for a persistent time period. Excessive time has elapsed between battery separate and subsequent battery reconnection. Battery volts exceeded limits for a persistent period of time, while engine speed is greater than idle and control power is ON; further defined by the following subID: :01Control battery volts below 20 V DC :02Control battery volts above 32 V DC :03Cranking battery volts below 20 V DC :04Cranking battery volts above 32 V DC
629Barometric Pressure
SYS EVENT
Barometric pressure sensor signal exceeded limits for a persistent period of time, further defined by the following subID: :01Barometric pressure sensor value too low :02Barometric pressure sensor value too high
630Motor Blower Pressure
SPEED LIMIT
Motor blower pressure signal exceeded limits, indicating a problem with the sensor, duct work, or axle box sensor. Further defined by the following subID: :01No cooling air :02Low voltage :03High voltage :04Sensor reversed
631Ambient Temperature
SYS EVENT
Ambient temperature sensor signal exceeded limits for a persistent period of time, further defined by the following subID: :02Ambient temperature signal too high
141

Event Description
632TCI Configuration File

NO PROPEL
A problem with the TCI configuration file has been detected, further defined by the following subID: :01File not loaded :02File loaded improperly, resulting in bad CRC :03Wrong version of file loaded
633BBRAM Battery Failure 634Truck Overloaded Restrictive 635Truck Overloaded NonRestrictive 636Aux Inverter Faults
SYS EVENT NO PROPEL SYS EVENT SYS EVENT
Batterybacked RAM (BBRAM) battery has failed. Truck operation restricted when overloaded signal received and TCI configured for restrictive response. Truck operation not restricted when overloaded signal received and TCI configured for nonrestrictive response. Auxiliary blower control failure has occurred. :00No fault condition; initial state on application of control power :01Low DC bus voltage detected during powerup :02High DC bus voltage detected during operation :03Overcurrent condition detected during operation :05High DC bus voltage detected during operation :06High DC bus voltage detected after phase controller powerup :07Low DC bus voltage detected after phase controller powerup :08High DC bus voltage detected during operation :09Overcurrent condition detected after phase controller powerup :10Sustained current overload exists (above rated conditions but below component safe operating range) :11Overcurrent fault due to low DC link voltage :12Sustained current overload fault due to low DC link voltage :13IGBT protection circuit detected overcurrent :14Low or missing AC input voltage detected
638Engine cranking timeout 639Engine Start Request While Running 640Accel Pedal Too High 641Accel Pedal Too Low 696Unexpected CPU Reset 698PTU Data Store
SYS EVENT SYS EVENT
The diesel engine was cranking longer than the maximum allowed cranking time. An Engine Start Request was received while the diesel engine was running. The engine speed must be greater than 600 rpm and the start request signal must be present for three seconds minimum for this event to be logged. Accelerator Pedal input is greater than the maximum value for a specified period of time. Accelerator Pedal input is less than the minimum value for a specified period of time. The TCI CPU was reset while the system was in Self Load, Propel, Retard, or Ready mode. 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.
NO PROPEL SYS EVENT SYS EVENT SYS EVENT
142
10. SPECIAL OPERATIONS AND TESTS
10.1. WELDING ON THE TRUCK

When welding on trucks equipped with GE control panels, connect the welders ground cable such that welding current does not flow through the trucks control wires or cables. This ground connection should be made directly to (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 box or cab. If welding is being done on the control box 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. This practice can cause more damage than it prevents. It puts unnecessary cycles on the connector pins and may cause loose or dirty pins which could result in a control system failure.
10.2. MOVING TRUCK WITH ONE WHEEL MOTOR

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. When using this special 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 only one wheel motor.
1. With truck stopped and the engine running, apply the Parking Brake (propulsion system commanded to REST mode) and place the Direction Selector handle in the NEUTRAL position.
CAUTION: Single inverter/wheel motor operation of the truck should only be done with an empty truck. Operation of a loaded truck with one inverter/wheel motor may result in damage to that wheel motor.
2. 3. Remove the load, if present, from the truck. On the right side of the main control cabinet, move the affected inverter cutout switch to the CUTOUT position. This will disable that inverter/wheel motor combination from either accelerating or retarding the truck. Release the Parking Brake (propulsion system exits REST mode). Place the Direction Selector handle in FORWARD and move the truck to the desired location.
4. 5.
143
10.3. VOLTAGE ATTENUATION MODULE (VAM) 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. Resistance to ground or to any other points on the VAM should be infinite. Refer to the receptacle and plug diagrams in the system schematic for connector arrangement. VAM1 AND VAM2, 17FM702, 8 CHANNELS High Voltage Stud VH1 VH2 VH3 VH4 VH5 VH6 VH7 VH8 Low Voltage Connector CN15 CN16 CN110 CN114 CN17 CN13 CN12 CN11
VAM1 AND VAM2, 17FM681, 5 CHANNELS High Voltage Stud VH1 VH2 VH3 VH4 VH5 Low Voltage Connector CN11 CN12 CN13 CN14 CN15
10.4. CURRENT MEASURING MODULE CHECKS

With all wiring removed from the suspect current measuring module, the following are the nominal resistance values between the connection points indicated: S S S Between + and : greater than 20 Kohm Between M and + : greater than 1 Megohm Between M and : greater than 1 Megohm
144
10.5. LINK CAPACITANCE TEST

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. 2. Engine running and DC link charged. Truck stopped with no direction commanded and accelerator pedal not pressed.
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 wPTUt screen. This screen can be accessed as follows: 1. 2. 3. 4. 5. Connect the wPTUt to the PSC serial port (located in the operator cab), start the GE OHV wPTUt Toolbox, enter password, select PSC Panel, select appropriate truck type, and click on LOGIN to wPTUt Toolbox . From the window browser, select PTU Screens > PSC > Normal_Operation > Tests > Capacitance Test (Fig. 79). The Capacitance Test screen is now displayed and the test data can be viewed (Fig. 80). Close the Capacitance Test display screen by clicking on the X in the upper right corner of the screen. Click on the Target button to go back to the GE OHV wPTUt Toolbox Login screen, close the wPTUt Toolbox, shut down the PTU, and disconnect it from the PSC serial port.
FIG. 79. PSC CAPACITANCE TEST SCREEN ASSESS SEQUENCE. E44403.
145
FIG. 80. CAPACITANCE TEST SCREEN. E44404.
146
11. PHASE MODULE AND GATE DRIVER TROUBLESHOOTING GUIDE
11.1. INTRODUCTION
WARNING: Traction 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 equipment. 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 as well before proceeding with maintenance or troubleshooting. Failure to do so may result in personnel injury or death. WARNING: When troubleshooting this truck, unless stated otherwise the truck engine should be shut down and power removed from the DC link. At 400 RPM engine speed, the DC link is normally commanded 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. TEST/INSPECTION PROCEDURE

1. Check the wPTUt PSC Real Time Data screen to determine if the inverter involved in the phase module fault is active or not. Run the Inverter VI Test as follows to determine if the fault occurs again: a. Apply the Parking Brake (propulsion system commanded to REST mode) and place the Direction Selector switch in the NEUTRAL position. b. Start and run the engine. c. When the engine has achieved its idle speed, release the Parking Brake (propulsion system exits REST mode). d. Monitor status messages on the wPTUt 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, there should be the message Completed . e. If no faults are logged, and there is no recent history of inverter faults, the truck can be released for service. If faults are logged proceed with the remainder of this troubleshooting section. 3. Shut down the engine but maintain control power to the propulsion control. Go to the phase module in question as identified by the fault, and pull out its gray fiber optic connector. The red LED should be ON.
2.
WARNING: When viewed under some conditions, the optical port may expose the eye beyond the maximum permissible exposure recommended in ANSI z136.2, 1993.
a. If the red LED is ON, the IGBT on the phase module is not shorted. Gate drivers, however, can intermittently fail, therefore, the LED indication does not guarantee that the gate driver is OK. b. If the red LED is OFF, that is usually an indication that the IGBT on the phase module is shorted or the gate driver has failed. 147
4.
Check the gate drivers as follows: a. Disconnect the GDPC plug from the gate driver and check for 90 to 100 V AC @ 25 Hz square wave signal at the circular plug. (A Simpson analog meter is recommended for this 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, unplug all the gate drivers on the inverter in question. Then plug them 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 falls below 90 V AC, replace that gate driver. e. Continue to check all the gate drivers for this 90 V AC threshold.
5.
If the gate driver and the IGBT test OK, but the truck has a recent history of repeated failures, replace the phase module. Inspect all laminated bus bars for damage. Use a voltohm meter to check resistance to ground on the DC link circuit. Using that same meter, check for short circuits on the DC link from the positive horizontal bus bar to the negative horizontal bus bar. Inspect all other phase modules for flash burns. Check all phase module fuses for continuity (there are two fuses in parallel per phase module).
6. 7.
8. 9.
148
12. 17FB144 AND 17FB147 CIRCUIT CARD TROUBLESHOOTING GUIDE
12.1. INTRODUCTION
Often, 17FB144 and 17FB147 boards used in 150 ton OHV propulsion systems have no defects found when returned 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 describes a procedure to use Microsoft HyperTerminal to troubleshoot 17FB144 and 17FB147 boards.
12.2. CARD EDGE LIGHTS

There are two LED indicators on the bottom front edge of the boards defined as follows: LED1 / WDTIME Watchdog timer indicator. ON Watchdog Timer timed out. OFF Watchdog Timer 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 bootup 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 downloaded to, if the LEDs are flashing.
NOTE: If using HyperTerminal while LEDs are flashing, text will be continuously scrolling with a variable time delay between messages.
The 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 indicator is ON solid. Typical LED patterns for Version 19 software are listed in TABLE 6.
12.3. TROUBLESHOOTING PROCEDURE

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 PATTERNS FOR VERSION 19 SOFTWARE
BOARD PROGRAMMED (PROGRAM IN FLASH MEMORY)? OTHER CPU BOARD PROGRAM MED?
CONDITION
BOARD PROBLEM
17FB144 BOARD WDTIME LIGHT FATL LIGHT ON solid ON solid or 2 flashing OFF OFF or 4 1. xxx 2. Flash 3. xxx 4. xxx 5. Repeat after variable time delay OFF 1. Flash
17FB147 BOARD WDTIME LIGHT xx FATL LIGHT ON solid ON solid or 2 flashing OFF OFF or 4 1. Flash twice 2. Flash 3. 1 sec. delay 4. Flash 5. Repeat after variable time delay OFF 1. Flash 2. 1 sec. delay 3. Flash 4. 3 sec. delay 5. Flash twice 1. Flash 2. 1 sec. delay 3. Flash Flash once only, then OFF OFF OFF or 4 1. xxx 2. Flash 3. xxx 4. xxx 5. Repeat after variable time delay OFF 1. Flash
1 2 3 4
Running / Powerup Running / Powerup Running Running
Major failure 5V power 1 supply low None / Onboard battery low 3 None / Onboard battery low 3
xx xx Yes No
xx xx xxx Yes
xx ON solid or 2 flashing OFF OFF or 4 1. Flash twice 2. Flash 3. 1 sec. delay 4. Flash 5. Repeat after variable time delay OFF 1. Flash 2. 1 sec. delay 3. Flash
5 6
Running Powerup
None / Onboard battery low 3 None / Onboard battery low 3
No Yes
No xx
Powerup
None / Onboard battery low 3 None but serial com cable problem between board and PTU 5
No
xx
1. Flash 2. 1 sec. delay 3. Flash Flash once only, then OFF
1. Flash
1. Flash
Powerup with PTU attached
xx
xx
Flash once only, then OFF
Flash once only, then OFF
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, lights may flash. Lights my also flash if the 5 V power supply voltage is oscillating.
3
Low battery will not effect microprocessor board operation. However, statistical data and other values stored in RAM may be lost.
4 5
Light pattern can vary per board as well as if the wPTUt (PC) is connected to the relevant board serial port.
Open wPTUt serial communication ground wire with wPTUt connected can cause board bootup (buck) routine to not run during powerup.
150
See Sheet 2 of 2
FIG. 81. 17FB144 AND 17FB147 BOARD TROUBLESHOOTING PROCEDURE (SHEET 1 OF 2). E44732.
151
See Sheet 1 of 2
FIG. 81. 17FB144 AND 17FB147 BOARD TROUBLESHOOTING PROCEDURE (SHEET 2 OF 2). E44732.
152
12.4. USING HYPERTERMINAL TO COMMUNICATE TO 17FB144 AND 17FB147 BOARDS

HyperTerminal is a terminal emulator package that is included in Microsoft Windows 95/98 and 2000. This software package can be used to communicate to either CPU board through the normal PTU connection. It allows access to bootup text that can be used to determine if communications with the CPU are active, the CPU board has passed self tests, whether software has been loaded onto the board, if the software is running (and PTU communication protocol is active), and if any other abnormal situation exists. The CPU board flash memory can also be erased using HyperTerminal. This will subsequently allow PTU downloading of the software in cases where the CPU board is cycling messages and the PTU cannot break in and begin downloading. HyperTerminal is used to break into the bootup routine and then flash memory is erased.
12.4.1.
Pitfalls/Traps When Using HyperTerminal
If having communications problems with the PTU, it is common to close the PTU window and try again. If the window is closed while the PTU is trying to communicate, the COM1 port may not be released by the PTU and HyperTerminal will not be able to connect to it. In this instance, HyperTerminal will generate 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 reenabling 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. E44733. 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 window is from only the present session only, start a new connection. The 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.
12.4.2.
Accessing HyperTerminal
Before beginning, connect the serial cable to the relevant CPU board serial port and to the COM1 port on the PC. 1. HyperTerminal is located under the 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 wPTUt login window by selecting the Terminal Emulator Mode radio button (Fig 4).
2. The window shown in Figure 84 will appear and ask to name the new connection and pick an icon. If a connection was previously defined, just click Cancel. If defining a new connection, type in the new name, select an icon from those provided, and click OK. The Connect To window shown in Figure 85 will appear. Select Direct to Com1 in the Connect using menu selection and then click OK. The COM1 Properties window shown in Figure 86 will appear. Select the following and then click OK. (Advanced 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)
3. 4.
Double click here
FIG. 83. HYPERTERMINAL ICON. E44734.
154
FIG. 84. HYPERTERMINAL NEW CONNECTION WINDOW. E44735.
FIG. 85. HYPERTERMINAL CONNECT TO WINDOW. E44736
155
FIG. 86. HYPERTERMINAL COM1 PROPERTIES WINDOW. E44737

5. After the COM1 properties are set, the main HyperTerminal window will look like that shown in Figure 87, if HyperTerminal is able to connect to the COM1 port.
NOTE: The lower left hand banner will say Connected and count the connection time. This only indicates that HyperTerminal has access to the COM1 port, NOT that HyperTerminal can talk to the connected CPU board.
6. If HyperTerminal cannot connect to COM1, a message window appears that says Unable to Open COM1 and the banner will say Disconnected as shown in Figure 88. If this happens, try to reset the COM1 port by disabling it and reenabling it at the window previously shown in Figure 82. If this does not work, reboot the computer. Once HyperTerminal is connected to the COM1 port, cycle control power to the connected CPU board. The screen will appear as shown in Figure 89 if the CPU board is already programmed and running. Only the 17FB144 board will show the text line pertaining to the battery test. Figure 89 shows the HyperTerminal main window scrolled backwards 1 line to show the complete text that comes out of the CPU board.
7.
NOTE: The 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.
8. The screen will appear as shown in Figure 90 if the CPU board is not programmed. Only the 17FB144 board 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 flash memory (program) on a CPU board, the bootup routine must be interrupted. To do this, hold down the TAB key and cycle 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 bootup routine has been interrupted, the CPU board flash memory (program) can be erased by typing 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 appear if the flash memory was erased successfully. 11. An open PTU serial communication ground wire with the PTU connected can cause the CPU board bootup (buck) routine to not run during powerup. If this happens, the text in HyperTerminal will stop after the 25MHZ board detected message as shown in Figure 93. 12. When exiting HyperTerminal, it will ask you if you want to save the session. If you click OK, you can select the session name the next time you enter HyperTerminal and you will not have to perform the communications setup.
NOTE: If you do save the session, any text that was in the HyperTerminal window (including that scrolled past the view window) will also be saved.
After the initial save, HyperTerminal saves session text (without asking) every time you close it. If it is necessary to verify that the text stored in the HyperTerminal 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. E44738
157
Message window
Banner shows Disconnected
FIG. 88. HYPERTERMINAL MAIN WINDOW WHEN NOT CONNECTED TO COM1 PORT. E44739
158
Light blue screen only because screen scrolled back one line
This line only seen for 17FB144 board (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. E44740.
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. E44741
160
Hold TAB key down until this message appears while cycling power.
FIG. 91. HYPERTERMINAL MAIN WINDOW AFTER CYCLING CONTROL POWER, WITH TAB KEY HELD DOWN (INTERRUPTING BOOTUP ROUTINE). E44742.
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. E44743
162
FIG. 93. HYPERTERMINAL MAIN WINDOW WHEN BOOTUP (BUCK ROUTINE) DOES NOT RUN DUE TO OPEN PTU SERIAL CABLE GROUND WIRE WITH THE PTU CONNECTED. E44744.
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 marked with an asterisk (*) may not be present in all control groups. Refer to truck specific schematic for configuration details.
TABLE 7. GLOSSARY
Term AFSE AFSER ALT Description Alternator Field Static Exciter (17FM689) panel regulates the current in the alternator field. Alternator Field Static Exciter Resistor facilitates battery boost to AFSE. AFSER is used in the low side driver circuit. 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. Ambient Temperature Sensor, located in the air inlet to the inverters, senses ambient air temperature. PSC Analog Input/Output Card (17FB173) provides signal conditioning for analog signals to/from the Propulsion System Control Panel. This card monitors system voltages and currents along with frequency tachometer inputs from the hydraulic blower system and the engine. It also contains the digital alternator field control system. TCI Analog Input/Output Card (17FB160) provides signal conditioning for analog signals 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. Barometric Pressure Sensor provides a barometric pressure signal to the control system used in the calculations of control system cooling requirements. Battery Power Fuse provides overload protection to the control equipment. OEM supplied Battery Switch is used to connect/disconnect battery voltage from the truck control equipment. Battery Blocking Diode provides isolation between the Battery Line Filter output voltage and truck battery voltage. Battery Filter Capacitor Assembly is used to temporarily sustain control power to the electronics panels in the presence of battery voltage dips and outages. Battery Filter Capacitor Resistor is used to limit inrush current to the Battery Filter Capacitor. NOTE: Used only in the 17KG527B1 Control Group configuration. 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. 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 Resistors in the Retarding Grid assembly during dynamic retarding operations and selfload testing. Grid Blower Motor #1 Current Measuring Module used to measure the DC current flow through the grid blower motor. Inverter #1 Filter Capacitors store and filter the Inverter #1 DC bus voltage to provide instantaneous power when the Inverter1 GTO/IGBT Phase Modules first turn on. Capacitor Charge Indicating Lights #1 and #2 are illuminated when 50 volts or more is present on the DC link (the DC bus that connects the Alternator output, Chopper Module/Resistor Grid circuits, and traction Inverters). 165
AMBTS ANALOG I/O CARD (PSC)
ANALOG I/O CARD (TCI) BAROP BATFU BATTSW BD1 BFC BFCR* BLFP*
BM1
BM1I CCF1, CIF11, CIF12, CIF21, CIF22 CCL1, CCL2
TABLE 7. GLOSSARY (Contd)

Term CCLR1, CCLR2 Description 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. Chopper Diode #1, #2 same as positive IGBT module. Chopper Fuses same as inverter phase fuses. 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 17KG527B1 Control Group configuration. Alternator Field Current Sensor detects the amount of current flow through the Alternator field winding. Alternator Tertiary Current Sensing Module detects the amount of AFSE current supplied by the Alternator tertiary winding. 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. Phase 1A and 1B Current Sensing Modules detect the amount of current flow through the A and B phases of Traction Motor #1. Phase 2A and 2B Current Sensing Modules detect the amount of current flow through the A and B phases of Traction Motor #2. Control Power Relay (17LV66) is picked up when the Key Switch and Control Power Switch are closed. CPR contacts are used to connect/disconnect battery voltage to the propulsion system. Control Power Blocking Diode provides diode blocking between the control power switch input and the control power digital output. CPR Suppression Module limits the transient voltage induced into the battery system whenever power to the CPR coil is interrupted. Control Power Switch (mounted on the diagnostic panel) is used to connect/disconnect battery voltage to/from the control system. System CPU Card (17FB147) in the ICP provides control system processing and serial link communication. System CPU Card (17FB144) in the ICP provides the processing of truck systems I/O and serial link communication. Laminated bus bar for IGBT inverter and chopper. 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. System Digital Input/Output Card (17FB104) provides batterylevel drive signals to control relays, contactors and LEDs; and receives batterylevel status feedbacks of relays, contactors and switches. System Digital Input/Output Card (17FB104) provides batterylevel drive signals to control relays, contactors and lights; and receives batterylevel status feedbacks of relays, contactors and switches. Engine Speed Sensor that is mounted on the alternator, which is directly coupled to the engine. 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.
CD1, CD2 CF CGBM1, CGBM2*
CMAF CMT CM1, CM2 CM1A, CM1B CM2A, CM2B CPR
CPRD CPRS CPS CPU CARD (PSC) CPU CARD (TCI) CVB DID
DIGITAL I/O CARD (PSC) DIGITAL I/O CARD (TCI) ESS EWMS
166

Term FB1L, FB2L FB1R, FB2R, FBCL FDR* FIBER OPTIC ASSEMBLY FP GDPC GF GFCO GFM GFR GFRS GFS GRR GRR9 GRR10 I1VB, I2VB ICP INV1 TMC CARD Description Filter Capacitor Bus Bar which connects the leftside filter capacitor to vertical laminated bus bar. Filter Capacitor Bus Bar which connects the rightside filter capacitors to vertical laminated bus bar. Filter Discharge Resistor Panel is a resistor divider connected across the DC link. FDR discharges the DC link. Fiber Optic Assembly provides voltage and noise isolation for the control and feedback signals between the Propulsion Control Panel and the Phase/Chopper Modules. Filter Panel (17FM460) is connected across the threephase output of the Alternator to filter electrical noise. Gate Drive Power Converter provides gate drive power for IGBT phase and chopper modules. GDPC contains both GDPC1 and GDPC2. Generator (Alternator) Field Contactor (17CM55) connects the AFSE to the Alternator field. GF is controlled by the Propulsion Control Panel. GF contactor cutout 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. 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. Generator Field Relay (17LV66) picks up with the GF contactor and is used for alternator field control. GFR Suppression Module limits the transient voltage induced into the battery system whenever power to the GFR coil is interrupted. GF Suppression Module limits the transient voltage induced into the battery system whenever power to the GF coil is interrupted. Ground Resistor Panel is a voltage divider connected across the DC link, used with GRR9 and GRR10 to detect system ground faults. GRR9 is used in conjunction with GRR and GRR10 to measure ground fault current. GRR10 is used in conjunction with GRR and GRR9 to measure ground fault current. Laminated vertical bus bar for IGBT inverter and chopper. Control electronics panel (17FL375) containing all functions formerly provided by the separate PSC and TCI panels. Inverter #1 Traction Motor Control (TMC) Card (17FB172) combines the functions previously provided in the CPU (17FB138) and I/O (17FB134) cards into a single inverter control card. Inverter #2 Traction Motor Control (TMC) Card (17FB172) combines the functions previously provided in the CPU (17FB138) and I/O (17FB134) cards into a single Inverter Control Card. Inverter #1 Cut Out Switch (located in the Operator Interface area of the Main Control Cabinet), when closed, is used to cut out Inverter #1. NOTE: Not used on B1 or later configurations. Inverter #2 Cut Out Switch (located in the Operator Interface area of the Main Control Cabinet), when closed, is used to cut out Inverter #2. NOTE: Not used on B1 or later configurations. OEM supplied Keyswitch is used to connect/disconnect battery voltage to/from CPR. 167
INV2 TMC CARD
I1CO*
I2CO*
KEYSW

Term LEDP* Description LightEmitting Diode Panel (located in the Operator Interface area of the Main Control Cabinet) provides a visual indication of system status: CPR SYS RUN NAFLT TEST REST LINKI is illuminated when CPR is picked up is illuminated when ICP (or PSC, as equipped) is operational is illuminated when a restrictive event condition is present is illuminated when the system is in the Test state is illuminated when the system is in the Rest state with power removed from the DC link
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). Inverter phase fuses, mounted on laminated bus bars, provide short circuit protection for inverter phases to limit damage from IGBT failures. Phase Modules (IGBT, 17FM796) provide the positive driving voltages for each of the three windings of Traction Motor #1. Phase Modules (IGBT, 17FM797) provide the negative driving voltages for each of the three windings of Traction Motor #1. Phase Modules (IGBT, 17FM796) provide the positive driving voltages for each of the three windings of Traction Motor #2. Phase Modules (IGBT, 17FM797) provide the negative driving voltages for each of the three windings of Traction Motor #2. Power Supply (17FH41) which provides +5VDC, 15VDC, 24VDC regulated voltage. Propulsion System Controller, is one of the CPU cards (17FB147) in the ICP panel. Rectifier Diode Panel (17FM528), also denoted as the main rectifier panel, converts the output threephase, AC voltage from the Alternator to DC voltage to power the two Inverters. Grid Resistors dissipate power from the DC link during retarding, selfload, and Inverter Filter Capacitor discharge operations. 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. Retard Contactor, when closed, connects the Grid Resistors to the DC link during retarding, selfload, and Inverter Filter Capacitor discharge operations. RP1 Suppression Module limits the transient voltage induced into the battery system whenever power to the RP1 coil is interrupted. Battery Boost Resistor limits surge current in the Alternator field circuit when the GFR contacts initially close. Traction Motor Speed Sensors which provide Traction Motor speed signals to the respective Inverter control cards. Front Wheel Speed Sensors. Front Wheel Speeds are monitored for wheel slips/slide control logic.
PF1A, PF1B, PF1C PF2A, PF2B, PF2C PM1A+, PM1B+, PM1C+ PM1A, PM1B, PM1C PM2A+, PM2B+, PM2C+ PM2A, PM2B, PM2C PS PSC RD
RG1A, RG1B, RG1C, RG2A, RG2B, RG2C, RG3A, RG3B, RG3C, RGBM*
RP1 RP1S R1 SS1, SS2 SS3, SS4
168

Term TCI TH1 TM1, TM2 Description Truck Control Interface, is one of the CPU cards (17FB144) in the ICP panel. Alternator Field Thyrite (Varistor) protects the Alternator field circuit from voltage transients. Motorized Wheels 1 and 2 each consisting of a Traction Motor and a Transmission Assembly. The threephase asynchronous Traction Motors convert electrical energy into mechanical energy. This mechanical energy is transmitted to the wheel hub through the speed reducing Transmission Assembly. Voltage Attenuation Modules #1 and #2 (17FM702) are eightchannel devices for the inverters. VAM1 and VAM2 are used to attenuate high voltage motor to line neutral and DC link values to a level acceptable to the control electronics. Voltage Attenuation Modules #3 and #4 (17FM681) are fivechannel devices for system use. VAM3 and VAM4 are used to attenuate high voltages to a level acceptable to the control electronics.
VAM1, VAM2
VAM3, VAM4
169
170
14. SOFTWARE VERSIONS
14.1. VERSION 19, JULY 2002

Version 19 was developed to support enduser 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 MSWindows based PTU (wPTUt) listed in TABLE 8.
NOTE: The FB173 card software is downloaded automatically at startup by the system.
General information 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 Controller Software Propulsion System Controller (PSC) Truck Control Interface (TCI) Inverter IMC Version (17FB138/17FB134) Inverter TMC Version (17FB172) Windows PTU and toolbox (Release 1.0) AC PTU AC Mine and OEM Configuration Utility OHV Download Utility OHV Datalogger Utility OHV Datalogger Graphing Utility FB173 Card Software (17FL375 Panel Only) 17FB173 Card CPLD Version (17KG526, 527 Only) Software Name 17FB173 MicroController Software (17KG526, 527 Only) 17FB173 Alternator Field Programmable Gate Array (FPGA) (17KG526, 527 Only) 17FB173 Speed FPGA (17KG526, 527 Only) 3 or Higher Version 2.42 3.2, 01/28/01 7.3, 09/26/00 17FB173 Card Location 17FB173 Card 17FB173 Card 17FB173 Card 19.03 19.03 2.0 X16, July 2001 B6.4 PC PC PC PC PC 19.03a 19.03a 02.19.03 05.19.03 17FL320 or 375 17FL349, 373, or 375 17FL320 17FL320 or 375 Version Location
171
14.2. VERSIONS INFORMATION TABLE 9. SOFTWARE VERSIONS INFORMATION

Version 19 Date Released July 2002 GETS SMI # 41A322501BD Status Active Notes Current version for all propulsion system models; includes support for wPTUt Added support for KG526 and KG527 groups General improvements General improvements Added support for high altitude operation Added support for Tar Sands operation First official version for KG498 groups
18 17 16 14 13 12
May 2001 August 1999 October 1998 June 1998 October 1997 September 1997
41A322501BC 41A322501BB 41A322501BA N/A N/A N/A
Obsolete Obsolete Obsolete Obsolete Obsolete Obsolete
172
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GET6869

VTI For 150 Ton AC OHV Propulsion Systems, GET6869

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

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

GET6869, VTI For 150 Ton AC OHV Propulsion Systems

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

6. TRUCK STARTUP PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

VTI For 150 Ton AC OHV Propulsion Systems, GET6869

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

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

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

11. PHASE MODULE AND GATE DRIVER TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

GET6869, VTI For 150 Ton AC OHV Propulsion Systems

12. 17FB144 AND 17FB147 CIRCUIT CARD TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

13. GLOSSARY OF TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 14. SOFTWARE VERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

5. EVENT CODE DESCRIPTIONS AND INFORMATION 7. GLOSSARY

VTI For 150 Ton AC OHV Propulsion Systems, GET6869

GET6869, VTI For 150 Ton AC OHV Propulsion Systems

LIST OF ILLUSTRATIONS (Contd)

VTI For 150 Ton AC OHV Propulsion Systems, GET6869

LIST OF ILLUSTRATIONS (Contd)

GET6869, VTI For 150 Ton AC OHV Propulsion Systems

VTI For 150 Ton AC OHV Propulsion Systems, GET6869

TOOLS AND TEST EQUIPMENT

HANDLING ELECTRONIC PANEL PRINTED CIRCUIT CARDS

* Trademark of GE Transportation Systems ** Trademark of James G. Biddle Co. 1

GET6869, VTI For 150 Ton AC OHV Propulsion Systems

VTI For 150 Ton AC OHV Propulsion Systems, GET6869

2. PORTABLE TEST UNIT (PTU) DESCRIPTION

OHV wPTUt TOOLBOX OVERVIEW

2.2.1. RealTime Data

2.2.2. Stored Event Data

2.2.3. Statistical Data

GET6869, VTI For 150 Ton AC OHV Propulsion Systems

2.2.4. Setting Propulsion System Configuration Options

2.2.5. Software Downloading

2.2.6. Data Analysis

2.2.7. System Configuration

2.2.9. Integrated Help

wPTUt SCREEN SELECTIONS

An outline of the wPTUt startup screen selections is shown in Figure 1.

VTI For 150 Ton AC OHV Propulsion Systems, GET6869

GET6869, VTI For 150 Ton AC OHV Propulsion Systems

FIG. 2. TCI WINDOW BROWSER SCREEN SELECTIONS. E44410B.

VTI For 150 Ton AC OHV Propulsion Systems, GET6869

FIG. 3. PSC WINDOW BROWSER SCREEN SELECTIONS. E44411B.

GET6869, VTI For 150 Ton AC OHV Propulsion Systems

FIG. 4. wPTUt TOOLBOX STARTUP SCREEN. E44340B.

wPTUt STARTUP SCREEN

VTI For 150 Ton AC OHV Propulsion Systems, GET6869

VIEW DATALOGGER AND DATA GRAPH SCREENS

SAVING SCREEN DISPLAYS

FIG. 5. START MENU PASSWORD UTILITY. E45148.

GET6869, VTI For 150 Ton AC OHV Propulsion Systems

VTI For 150 Ton AC OHV Propulsion Systems, GET6869

3. SELECTED SCREEN DESCRIPTIONS AND FUNCTIONS

PRODUCT SERVICE DATA SCREEN

TRUCK SPECIFIC DATA SCREEN

GET6869, VTI For 150 Ton AC OHV Propulsion Systems

VIEW OVERSPEEDS SCREEN

VTI For 150 Ton AC OHV Propulsion Systems, GET6869

SET WHEEL MOTOR TYPES SCREEN

MONITOR REAL TIME DATA