GET−6864B

VEHICLE TEST, DIAGNOSTIC, AND wPTUt

INSTRUCTIONS FOR
320 TON AC OHV PROPULSION SYSTEMS

Revisions are indicated by margin bars.

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by General Electric Company customers, if such reproduction is used exclusively in connection with equipment used in that customer’s
internal operation.
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 mainte-
nance. Should further information be desired or should particular problems arise which are not covered sufficiently for the user’s purposes, the matter should be referred to the General
Electric Company. Any applicable Federal, State or local regulations or company safety or operating rules must take precedence over any instructions given in this material. GE has no
obligation to keep the material up to date after the original publication.
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 GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

CONTENTS
Page
1. OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1. TOOLS AND TEST EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2. HANDLING ELECTRONIC PANEL PRINTED CIRCUIT CARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. PORTABLE TEST UNIT (wPTUt) DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1. wPTUt ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2. OHV wPTUt TOOLBOX OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.1. Real−Time Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.2. Stored Event Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.3. Statistical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.4. Setting Propulsion System Configuration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.5. Software Downloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.6. Data Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.7. System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.8. Self−Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2.9. Integrated Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2.10. One−Step Downloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3. wPTUt SCREEN SELECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4. wPTUt STARTUP SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5. Datalogger FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5.1. Setup Variables To Be Logged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5.2. Begin Datalogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.6. SAVING SCREEN DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.7. PASSWORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3. SELECTED SCREEN DESCRIPTIONS AND FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1. Product Service Data Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2. View Overspeeds Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3. Set Wheel Motor Types Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4. MONITOR REAL TIME DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4.1. PSC − Real Time Data Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4.2. PSC − Serial Link Data Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4.3. PSC − Analog Inputs Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4.4. PSC − Temperatures Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5. CHECK PSC MODE LOGIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5.1. Accessing PSC Logic Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.6. CHECK TCI ACCEL INHIBIT LOGIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.6.1. Accessing TCI Accel Inhibit Logic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.7. CONSOLIDATED TRUCK DATA SAVE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.8. REST MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.9. AUXILIARY BLOWER CONTROL FUNCTION AND MONITORING (KG498 ONLY) . . . . . . . . . . . . . . . . 22
4. CONFIGURATION FILES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1. GE Configuration FileName Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2. View Truck Configuration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3. GE/OEM Default Configuration Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.4. GE/OEM Configuration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.5. Saving New Configuration Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.6. Configuration File Destination Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.7. Configuration File Source Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5. INSTALLING AC PROPULSION SYSTEM SOFTWARE ON TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.1. Selecting The GE Configuration File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.2. SAVE EXISTING TRUCK DATA (Not Applicable to New Trucks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.3. PROGRAM TCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.4. PROGRAM PSC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.5. Program Inverters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.6. CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

CONTENTS (Cont’d)
Page
6. TRUCK STARTUP PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.1. CIRCUIT CONTINUITY AND RESISTANCE CHECKS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . 44
6.1.1. VOM Circuit and Component Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.1.2. Alternator Field Static Exciter (AFSE) P1 Adjustment (KG498 Only) . . . . . . . . . . . . . . . . . . . . . . . 45
6.2. MEGGER TEST FOR GROUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.2.1. Preparation For Megger Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.2.2. Megger Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.2.3. Restore Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.3. TROUBLESHOOTING FOR GROUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.4. LOW VOLTAGE POWER SUPPLY CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.4.1. Preparation for Power Supply Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.4.2. Power Supply Voltage Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.5. PSC AND TCI CARD CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.6. LOAD AC OHV PROPULSION SYSTEM SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.7. PSC MANUAL DIGITAL INPUT/OUTPUT TEST PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.8. PEDAL, POT, AND LEVER ADJUSTMENT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.9. CONFIGURATION CHANGES DUE TO CALIBRATION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.10. SET TIME AND DATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.11. CHECK COMMUNICATION STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.12. TCI ANALOG INPUT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.13. TCI MANUAL DIGITAL OUTPUT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.14. TCI MANUAL DIGITAL INPUT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.15. DIAGNOSTIC INFORMATION DISPLAY (DID) PANEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.16. INVERTER CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.16.1. Inverter Phase Module Command and Feedback Circuitry Checks . . . . . . . . . . . . . . . . . . . . . . . . 65
6.17. SELF LOAD TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.17.1. Preparation for Self Load Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.17.2. Checks Prior to Self Load Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.17.3. Self Load Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.18. INVERTER LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.19. FUNCTIONAL GROUND FAULT DETECTION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7. STATISTICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.1. GENERAL DESCRIPTION AND DEFINITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.2. VIEW STATISTICAL COUNTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.3. VIEW STATISTICAL PROFILES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.4. VIEW TRUCK STAT SERIAL REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.5. RESET STATISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.6. UPLOAD STATISTICAL DATA TO A FILE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.7. PROFILE (HISTOGRAM) DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
8. DIAGNOSTIC INFORMATION DISPLAY (DID) PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
8.1. DISPLAY SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
8.2. MODES DISPLAY (VERSION 19/20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
8.3. FAULTS DISPLAY (VERSION 19/20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
8.4. DISPLAY DESCRIPTIONS (VERSION 19/20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
8.4.1. Self Load Testing (Version 19/20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
8.4.2. Software Version Display (Version 19/20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
8.4.3. Link Capacitance Testing (Version 19/20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
8.4.4. Overspeed Setting (Version 19/20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
8.4.5. Gate Driver Test (Version 20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
8.4.6. Speedometer Test (Version 20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
8.4.7. View Parameters (Version 20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
8.4.8. View Stats (Version 20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
8.4.9. Inverter Cutout (Version 20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

CONTENTS (Cont’d)
Page
9. EVENT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
9.1. EVENT NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
9.2. EVENT RESTRICTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
9.3. TROUBLESHOOTING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
9.4. EVENT DATA ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
9.4.1. View TCI Event Summary Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
9.4.2. View TCI Trigger Data Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
9.4.3. View TCI Data Packs Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
9.5. Reset TCI Events Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
9.6. Erase TCI Events Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
9.7. Event and Inverter Parameters List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
10. SPECIAL OPERATIONS AND TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
10.1. WELDING ON THE TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
10.2. MOVING TRUCK WITH ONE WHEEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
10.3. VOLTAGE ATTENUATION MODULE (VAM) CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
10.3.1. A3PV Panel Check (KG498 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
10.3.2. LINKV Panel Check (KG498 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
10.4. Current Measuring Module Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
10.5. LINK CAPACITANCE TEST MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
10.6. AUXILIARY INVERTER SCR/IGBT TROUBLESHOOTING
(KG498 CONTROL GROUPS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
10.6.1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
10.6.2. SCR Check−Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
10.6.3. IGBT Check−Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
11. PHASE MODULE AND GATE DRIVER TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
11.1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
11.2. TEST/INSPECTION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
12. 17FB144 AND 17FB147 CIRCUIT CARD TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . 164
12.1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
12.2. CARD EDGE LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
12.3. Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
12.4. USING HYPERTERMINAL TO COMMUNICATE TO 17FB144 AND 17FB147 BOARDS . . . . . . . . . . . 166
12.4.1. Pitfalls/Traps When Using HyperTerminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
12.4.2. Accessing HyperTerminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
13. GLOSSARY OF TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
14. SOFTWARE VERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
14.1. VERSION 21, December 2005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
14.2. VERSION 19, JULY 2002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
14.3. PREVIOUS VERSIONS INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

iv
 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

LIST OF FIGURES
Figure Title Page

1. wPTUt Startup Screen Selections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2. TCI Window Browser Screen Selections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. PSC Window Browser Screen Selections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. wPTUt Toolbox Startup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. wPTUt PSC Datalog Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6. PSC Datalogger Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7. Datalog Version Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8. Start Menu − Password Utility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
9. PSC − Serial Link Data Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10. PSC Temperatures Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
11. PSC Logic Screens Access Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
12. PSC Ready Mode Logic Screen (Typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
13. PSC Propel Mode Logic Screen (Typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
14. PSC Retard Mode Logic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
15. TCI Accel Inhibit Logic Screen Access Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
16. TCI Accel Inhibit Logic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
17. Consolidated Truck Data Save Selection From Toolbar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
18. Consolidated Truck Data Save Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
19. Composition of a GE AC OHV Configuration Filename. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
20. OEM Configuration File Tree (Typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
21. Open AC Configuration Tool Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
22. View Configuration Files Screen Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
23. PTU Screens Configuration Browser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
24. Set GE / OEM Options Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
25. Set Wheel Motor Types Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
26. GE Product Service Data Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
27. Overspeeds Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
28. OHV PTU Programming Utility Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
29. Programming the Panel Status Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
30. 320 Ton Truck TCI SW Versions Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
31. TCI Set Time and Date Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
32. Reset and Erase TCI Events Selections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
33. TCI Reset Stats Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
34. PSC Software Versions Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
35. PTU Browser PSC Manual Test Screen Access Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
36. PSC Manual Test Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
37. PTU Browser TCI Real Time Menu Access Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

v
GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

LIST OF FIGURES (Cont’d)

Figure Title Page

38. TCI Analog Inputs Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

39. PTU Browser PSC Real Time Menu Access Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
40. PSC Analog Input Channels Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
41. PSC Real Time Data Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
42. PTU Browser Set Time and Date Screen Access Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
43. Set Time and Date Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
44. Browser TCI Real Time Data Screen Access Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
45. TCI Real Time Screen (Typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
46. PTU Browser TCI Manual Test Screen Access Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
47. TCI Manual Test Truck Status Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
48. TCI Manual Test Screen (Typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
49. PTU Browser PSC Configuration Menu Access Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
50. Inverter Parameters Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
51. Self Load Engine Test Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
52. TCI Stat_Menu Selections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
53. View Counters Screen Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
54. Mine Counters Screen (PSC_STATS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
55. View Profiles Screen Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
56. Mine Profiles Screen (PSC_STATS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
57. Stat Serial Report Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
58. Reset Stats Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
59. Stat Profile Mine Reset Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
60. Reset Box Question Selection Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
61. DID Panel Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
62. DID Panel Hierarchy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
63. DID Panel Example − Normal Display (No Faults). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
64. DID Panel Message Example − Fault Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
65. DID Panel Message Example − Faults Display Function Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
66. DID Panel Message Example − Fault Reset Function Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
67. DID Panel Message Example − Load Box Test Function Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
68. DID Panel Message Example − Load Box Test Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
69. DID Panel Message Example − Test Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
70. DID Panel Message Example − PSC Software Version Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
71. DID Panel Message Example − V20 Info Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
72. DID Panel Message Example − Link Capacitance Test Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
73. DID Panel Message Example − Overspeed Setting Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
74. DID Panel Message Example − Gate Driver Test Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

vi
 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

LIST OF FIGURES (Cont’d)

Figure Title Page

75. DID Panel Message Example − Gate Driver Test Warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
76. DID Panel Message Example − Gate Driver Test In Progress. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
77. DID Panel Message Example − Speedometer Test Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
78. DID Panel Message Example − Speedometer Test in Progress. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
79. DID Panel Message Example − View Parameters Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
80. DID Panel Message Example − View Parameters Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
81. DID Panel Message Example − View Stats Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
82. DID Panel Message Example − View Stats Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
83. DID Panel Message Example − View Stats Interval Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
84. DID Panel Message Example − Inverter Cutout Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
85. DID Panel Message Example − Inverter Cutout Status Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
86. TCI Event_Menu Screens Access Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
87. TCI Event Summary Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
88. TCI Trigger Data Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
89. TCI Data Packs Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
90. Reset TCI Events Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
91. Erase TCI Events Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
92. Events & Inv Params Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
93. PSC Capacitance Test Screen Assess Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
94. Capacitance Test Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
95. 17FB144 And 17FB147 Board Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
96. COM1 Serial Port Window Message for Proper Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
97. Hyperterminal Icon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
98. Hyperterminal New Connection Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
99. Hyperterminal Connect to Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
100. Hyperterminal COM1 Properties Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
101. Hyperterminal Main Window When Connected to COM1 Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
102. Hyperterminal Main Window When Not Connected to COM1 Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
103. Hyperterminal Main Window After Cycling Control Power, Program Installed and Running. . . . . . . . . . . . 173
104. Hyperterminal Main Window After Cycling Control Power, Program Not Installed. . . . . . . . . . . . . . . . . . . . 174
105. Hyperterminal Main Window After Cycling Control Power, With Tab Key Held Down
(Interrupting Boot−Up Routine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
106. Hyperterminal Main Window After Erasing CPU Board Flash Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
107. Hyperterminal Main Window When Boot−Up (Buck Routine) Does Not Run Dut to Open PTU
Serial Cable Ground Wire With the PTU Connected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

vii
GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

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 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

1. OVERVIEW

This document describes the recommended truck start−up and checkout procedures at an Original Equipment
Manufacturer (OEM) facility or a customer’s mine. Special programming of specific mine software requirements,
software updating, system verification procedures, and troubleshooting information are also included. Refer to
Section 14., SOFTWARE VERSIONS, for current software version features and previous version information.

These instructions cover 320 ton applications of the following GE OHV AC control groups:
S 17KG498 (2700 HP)
S 17KG526B (3500 HP)
S 17KG526C (2700 HP)
S 17KG535
NOTE: Screen content of the wPTUt* Toolbox display screens may vary slightly for different control
groups.

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 USER’S GUIDE, GEK−91712.

NOTE: No revision bars are shown due to this being 100% revised to cover the new wPTUt Toolbox
procedures for 320 Ton vehicles from the previous DOS−based PTU covered in GET−6864.

1.1. TOOLS AND TEST EQUIPMENT

The following are recommended tools and test equipment used in the start−up and troubleshooting of the AC
Off−Highway Vehicle (OHV) propulsion system:

1. Analog Multimeter and Digital Multimeter

2. Meggert**, 0 to 1500 volt max. (0−2000 Megohms) @ 2 mA max.

3. Portable Test Unit (PTU) loaded with GE Transportation Systems (GETS) OHV wPTUt Toolbox software.

4. PTU cable, 9−pin RS232 communications cable with 1 male end connector and 1 female end connector

5. 1/4 in. thin wall socket

6. Connector pin extraction and insertion tooling as follows:

a. Pin Extraction, Amp Pt. 305183 (for CNA−CNF (ICP connectors), PS [FH41] connector, Gate Drive Power
Supply Connectors, and VAM low voltage connectors)

b. Pin Insertion, Amp Pt. 91002−1 (refer to above connectors)

c. Pin Insertion, Amp Pt. 200893−2 (for high−density 104 pin connectors)

d. Pin Extraction, Pei−Genesis (ITT Cannon distributor) Pt. CET−F80−16 (external control interface
connectors CNX1−5)

e. Pin Insertion, Pei−Genesis (ITT Cannon distributor) Pt. CIT−F80−16 (refer to above connectors)

* Trademark of GE Transportation Systems

** Trademark of James G. Biddle Co.
GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

7. Fluke 89 IV or equivalent with capacitance measurement capability.

NOTE: If a need arises to disassemble one of the 104−pin backplane 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

It is not recommended to pull cards from the panel any more times than necessary when starting up, testing, or
welding on the truck. This practice can cause more damage than it prevents because it puts unnecessary cycles on
the connector pins and may cause loose or dirty pins that could cause a control system malfunction.

CAUTION: If cards must be removed from a panel, power to the panel must be turned OFF before removing
or inserting cards into the panel.

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 electricity−proof containers should be used.

2. PORTABLE TEST UNIT (wPTUt) 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 (this is the
CPLD version that shows up on the wPTUt Software Version screen).

All adjustments, setup procedures, and diagnostic troubleshooting of the truck’s control system can be made
through this PTU when loaded with the OHV wPTUt Toolbox software.

NOTE: Refer to GEK−91712, OHV wPTUt User’s 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 9, Glossary.

2
 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

2.2. OHV wPTUt TOOLBOX OVERVIEW

NOTE: Refer to GEK−91712, OHV wPTUt User’s 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. Real−Time 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 real−time 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
on−board diagnostic system. Event data can be viewed in many formats including summaries or more detailed
frame−by−frame snapshots.

2.2.3. Statistical Data

The wPTUt Toolbox can be used to view statistical information stored by the propulsion system’s on−board
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 off−board.

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 system’s
central processing unit (CPU) cards. The propulsion system controller (PSC), truck control interface (TCI), and
Inverter software can be downloaded in a simple one−step 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. Real−time data can be graphed while on the truck or graphs can be generated
from data previously saved. All saved data can also be converted to Comma Separated Variable (CSV) format for use
by third−party software packages such as spreadsheets.

2.2.7. System Configuration

Many propulsion system parameters can be modified such as setting the on−board time and date, setting test
analog outputs, data logger setup, and system parameter modification.

3
GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

2.2.8. Self−Test

The wPTUt Toolbox software can be used to initiate or view propulsion system test information. Load−box mode,
the capacitance test, and manual self−test mode can be monitored.

2.2.9. 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. Mouse−over help also provides a short description of each screen field.

2.2.10. One−Step Downloading

All possible data to download from a truck, including event summaries, five−second data packs, and statistical data
can be downloaded with the touch of a button. This insures that the right information is gathered.

2.3. wPTUt SCREEN SELECTIONS

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

NOTE: Refer to GEK−91712, OHV wPTUt User’s 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.)

Login Screen (Figure 4)

Mode
Normal Mode
Offline/Training Mode
LOGIN to wPTUt 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 E−44409B

Figure 1. wPTUt Startup Screen Selections.

4
 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

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.)

NOTE: The Truck Type, Panel Type, and GE System selections are disabled in the Normal Mode.
Procedures in this manual are written for the Offline/Training Mode. Some portions of certain
procedures will be performed automatically when in the Normal Mode.

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 Figure 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 wPTU_ screens is contained in the Help menu. In the Menu Bar, click on
Help −> Application −> PTU Screen Help −> Desired Screen.

5
GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

PTU Screens
TCI
Normal_Operation
Real_Time (Figure 44)
Drive Status
TCI Real Time Data (Figure 45)
TCI Serial Link Data
TCI Analog Inputs (Figure 38)
TCI Temperatures
Logic (Figure 15)
Accel Inhibit Logic (Figure 16)
Configuration
TCI Parameters
TCI Analog Outputs
TCI Software Versions
TCI Datalog Setup
Special_Tasks
Event_Menu (Figure 86)
TCI Event Summary (Figure 87)
TCI Trigger Data (Figure 88)
TCI Data Packs (Figure 89)
TCI Log Events
Reset TCI Events (Figure 90)
Erase TCI Events (Figure 91)
Stat_Menu (Figure 52)
Serial−Cfg Report (Figure 57)
View Counters (Figure 53)
View Profiles (Figure 55)
Reset Stats (Figure 33)
Stat Start Date
Set Time and Date (Figure 31)
Events & Params (Figure 92)
Engine_Stopped_Tasks (Figure 39)
TCI Manual Test (Figure 48)
Ctrl_Z_to_return_to_menu

E−44410C

Figure 2. TCI Window Browser Screen Selections.

6
Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

PTU Screens
PSC
Normal_Operation
Real_Time (Figure 39)
PSC − Real Time Data (Figure 41)
PSC − Serial Link Data
PSC − Analog Inputs (Figure 40)
PSC − Temperatures (Figure 10)
Inverter BBRAM Data
FB173 Card Data (KG526 Groups Only)
Logic (Figure 11)
READY Logic (Figure 12)
PROPEL Logic (Figure 13)
RETARD Logic (Figure 14)
Configuration
PSC Parameters
PSC Analog Outputs
FB173 analog Outputs
Inverter Parameters (Figure 50)
Custom Parameters
PSC Software Versions (Figure 34)
PSC Datalog Setup
Tests (Figure 93)
Self Load Engine Test (Figure 51)
Temperatures
Capacitance Test (Figure 94)
Special_Tasks (Figure 42)
Event_Menu
PSC Event Summary
PSC Trigger Data
PSC Data Packs
PSC Log Events
Reset PSC Events
Erase PSC Events
Set Time and Date (Figure 43)
Events & Params (Figure 92)
Engine_Stopped_Tasks (Figure 35)
PSC Manual Test (Figure 36)
Ctrl_Z_to_return_to_menu

E−44411C

Figure 3. PSC Window Browser Screen Selections.

7
GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

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 (Figures 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 GEK−91712, OHV wPTUt User’s Guide, for complete information on installing and using
the wPTUt Toolbox software. Information on screen selections, navigation methods, and options is
also included.

E−44340B

Figure 4. wPTUt Toolbox Startup Screen.

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 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

2.5. DATALOGGER FUNCTION

A Datalogger function is contained in the GE OHV wPTUt Toolbox (GEOHVPTU 1.0). Use this functions as
described in the following sections.

2.5.1. Setup Variables To Be Logged

1. Connect the PTU to the desired serial port (PSC or TCI, 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. (Procedure is the same if TCI Panel is selected except screens titled for TCI.)
2. From the window browser, select PTU Screens −> PSC −> Normal_Operation −> Configuration −> PSC
Datalog Setup (Figure 5).
3. The PSC Datalog Setup screen is now displayed.
4. Click on the Datalogger Setup button to open the PSC Datalogger Setup screen, select the variables to
datalog and the rate at which to datalog them (Figure 6). Rate should be set to 20ms or slower for 15 or less
selected variables and to 40ms or slower for greater than 15 selected variables.
5. Click on the Exit button of the PSC Datalogger Setup screen to return to the PSC Datalog Setup screen.
6. Click on the numbered box in front of the variables to be datalogged. (Only the variables with a highlighted
green box will be datalogged.)
7. Close the PSC Datalog Setup display screen by clicking on the X in the upper right corner of the screen and
shutdown the wPTUt Toolbox.

E−46732A

Figure 5. wPTUt PSC Datalog Setup Screen.

9
GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

E−45369

Figure 6. PSC Datalogger Setup Screen.

2.5.2. Begin Datalogging

1. From the Start Menu go to START −> Program Files −> GEOHVPTU 1xx (current version) −> AC Tools −>
Datalog −> Start Datalogger.
2. The Datalog xx.xx (current version) screen is now displayed (Figure 7). The Datalog xx.xx screen will show
how long the recording can be performed based on the number of variables being recorded, the record rate,
and the available PC memory.
3. In the Menu section of the screen, two options are available as follows:
<W>rite data & quit − This option will stop datalogging and save the data to a file c:\program
files\GEOHVPTU 1xx (current version)\datalog\dlogxxx (xxx is a sequential number)
<A>bort − This option stops datalogging and does not create a file with the data.

The file generated in V19 software is a Space Delimited file that can be opened using any spreadsheet or text
editor. The file generated in V20 software is a Comma Delimited file (*.csv).

10
 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

E−45370

Figure 7. Datalog Version Screen.

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 GEK−91712, OHV wPTUt Toolbox User’s 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 filename
and location where the file is saved.

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

2.7. PASSWORDS

The ability to set passwords is provided using the Password Utility for the wPTUt toolbox (Figure 8). Refer to
GEK−91712, OHV wPTUt Toolbox User’s 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.

E−45148

Figure 8. Start Menu − Password Utility.

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 3.3. describe screens that are contained
in the wPTUt Configuration Utility. Sections 3.4. through 3.7. describe screens and functions that are contained in
the wPTUt Toolbox. The propulsion system’s REST mode function is described in Section 3.8. and the Auxiliary
Blower Control function and monitoring 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 (Figure 26). 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. 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.
2. Change the setting by deleting the existing setting (press any key and type the new setting, or simply type over
the existing data).
3. Press Enter to enter the modified setting. (The box color changes from white to blue, indicating that it has been
changed and will remain blue for the present session until the file is saved.)

NOTE: To keep the changes made to the Product Service Data settings, the file must be saved.

4. Click on File and Save. Pop−up messages notify the user that the changed data has been saved, and offer
other Save options.

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 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

3.2. VIEW OVERSPEEDS SCREEN

The View Overspeeds screen displays the current mine speed limit settings for the truck chosen (Figure 27).

3.3. 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
(Figure 25).

This screen is used to view and change 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. Either click in the desired box (outlined in red on the left of screen) or use the TAB key to toggle between the
boxes.
2. Change the setting by deleting the existing setting (press any key and type the new setting, or simply type over
the existing data).
3. Press ENTER to enter the modified setting. (The box color changes from white to blue, indicating that it has
been changed and will remain blue for the present session until the file is saved.)
4. Click on File and Save. Pop−up messages notify the user that the changed data has been saved, and offer
other Save options.

3.4. 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. 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.
2. From the window browser, select PTU Screens −> PSC −> Normal_Operation −> Real_Time −> PSC − Real
Time Data (Figure 39).
3. The PSC − Real Time Data screen is now displayed (Figure 41).

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

3.4.1. 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 9, Glossary, for definitions of the signal names that appear on this
and other screens.

The major sections of this screen are as follows:

1. Analogs − This section monitors the status and values of analog signals from devices such as current sensors,
voltage sensors, temperature sensors, etc.

2. Modes − This section provides information regarding the mode of operation, the direction of operation, the
commanded percent of propel or retard effort, communication status with TCI, etc.

3. Speeds − This section monitors various speed sensor signals and provides a processed truck speed
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, etc.

5. Digital Outputs (DO) − This section monitors the status of discrete output signals from PSC such as contactor
commands, panel enabling signals (e.g. GD1E, AFSE), indicating light control, etc.

6. Serial from TCI − This section monitors the status of discrete signals received by PSC from TCI over the
PSC−TCI serial link.

7. Serial to TCI − This section monitors the status of discrete signals provided by PSC to TCI over the PSC−TCI
serial link.

8. Inverters − This section monitors the status of various signals related to inverter operation including run status,
torque command, torque feedback, etc.

Close the PSC − Real Time Data display screen by clicking on the X in the upper right corner of the screen.

3.4.2. PSC − Serial Link Data Screen

1. From the window browser, select PTU Screens −> PSC −> Normal_Operation −> Real_Time −> PSC −
Serial Link Data (Figure 39).
2. The PSC − Serial Link Data screen is now displayed (Figure 9).
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.

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 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

E−44390B

Figure 9. PSC − Serial Link Data Screen.

3.4.3. PSC − Analog Inputs Screen

1. From the window browser, select PTU Screens −> PSC −> Normal_Operation −> Real_Time −> PSC −
Analog Inputs (Figure 39).
2. The PSC − Analog Inputs screen is now displayed (Figure 40).
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.

3.4.4. PSC − Temperatures Screen

1. From the window browser, select PTU Screens −> PSC −> Normal_Operation −> Real_Time −> PSC −
Temperatures (Figure 39).
2. The PSC − Temperatures screen is now displayed (Figure 10).
This screen monitors the status of various component temperatures provided either by sensors or by
calculations.
3. Close the PSC − Temperatures display screen by clicking on the X in the upper right corner of the screen.

15
GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

E−44392D

Figure 10. PSC Temperatures Screen.

3.5. 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.

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 real−time 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.

3.5.1. Accessing PSC Logic Screens

Perform the following to access the PSC Logic screens:

1. 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.
2. From the window browser, select PTU Screens −> PSC −> Normal_Operation −> Logic (Figure 11).
3. The PSC Logic menu of screens is now displayed. Double−click on the desired screen to display it.

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 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

E−45238A

Figure 11. PSC Logic Screens Access Sequence.

3.5.1.1. Ready Mode Logic Screen

1. From the Logic menu, double−click on READY Logic to select that screen (Figure 11).
2. The READY Logic screen is now displayed (Figure 12).
This screen displays the necessary requirements and the status of those requirements for the propulsion
system to achieve the READY Logic in preparation for either a subsequent PROPEL Logic or RETARD
Logic of operation.
3. Close the READY Logic display screen by clicking on the X in the upper right corner of the screen.

3.5.1.2. Propel Mode Logic Screen

1. From the Logic menu, double−click on PROPEL Logic to select that screen (Figure 11).
2. The PROPEL Logic screen is now displayed (Figure 13).
This screen displays the necessary requirements and the status of those requirements for the propulsion
system to achieve the PROPEL Logic of operation.
3. Close the PROPEL Logic display screen by clicking on the X in the upper right corner of the screen.

3.5.1.3. Retard Mode Logic Screen

1. From the Logic menu, double−click on RETARD Logic to select that screen (Figure 11).
2. The RETARD Logic screen is now displayed (Figure 14).
This screen displays the necessary requirements and the status of those requirements for the propulsion
system to achieve the RETARD Logic of operation.
3. Close the RETARD Mode display screen by clicking on the X in the upper right corner of the screen.
4. Click on the Target button to go back to the GE OHV wPTUt Toolbox Login screen, close the wPTUt
Toolbox, shut down the PTU, and disconnect it from the PSC serial port.

17
GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

E−44395C

Figure 12. PSC Ready Mode Logic Screen (Typical).

E−44396C

Figure 13. PSC Propel Mode Logic Screen (Typical).

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 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

E−44397C

Figure 14. PSC Retard Mode Logic Screen.

3.6. 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 real−time ladder diagrams that show the necessary truck functions and propulsion system operations
that must occur in order for an accel inhibit condition to occur. When activated, the various ladder diagram functions
are displayed reversed (highlighted). In this manner, this logic screen can be used as a troubleshooting aid in
diagnosing why an accel inhibit condition has occurred.

3.6.1. Accessing TCI Accel Inhibit Logic Screen

Perform the following to access the TCI Accel Inhibit Logic screen:

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.
2. From the window browser, select PTU Screens −> TCI −> Normal_Operation −> Logic −> Accel Inhibit
Logic (Figure 15).
3. The Accel Inhibit Logic screen is now displayed (Figure 16).

4. Close the Accel Inhibit Logic display screen by clicking on the X in the upper right corner of the screen.

5. 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.

19
GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

E−45239

Figure 15. TCI Accel Inhibit Logic Screen Access Sequence.

E−44363C

Figure 16. TCI Accel Inhibit Logic Screen.

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 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

3.7. 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. 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.
2. From the PTU Screens −> TCI screen Menu Bar, select UpLoad −> Consolidated Truck Data Save
(Figure17, refer to GEK−91712).

NOTE: Files are normally uploaded to the following:

c:/program files/geohvptu_xx/data_ac/<truck id date time>

3. 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 (Figure 18).
4. 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.
5. 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

E−45249

Figure 17. Consolidated Truck Data Save Selection From Toolbar.

3.8. 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 placing the REST rocker switch in the ON position. Placing this switch in the ON
position 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.

21
GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

E−44354B

Figure 18. Consolidated Truck Data Save Screen.

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.

2. It should always be done when the operator leaves the operator’s cab.

3. It is often done when the truck is expected to idle for an extended period of time.

4. It is often done during the course of truck start−up and troubleshooting.

To bring the GE OHV AC propulsion system out of REST mode, place the REST rocker switch in the OFF position.
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.

3.9. AUXILIARY BLOWER CONTROL FUNCTION AND MONITORING

(KG498 ONLY)

The GE OHV AC propulsion system is equipped with a blower that is dedicated to providing cooling air to the main
control cabinet and the wheelmotors. This auxiliary blower is powered and controlled by an auxiliary blower control
system located in the main control cabinet.

22
 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

The auxiliary blower control system has its own, separate DC link that provides power to the auxiliary blower control
inverter.

WARNING: Whenever the auxiliary blower control system is not shutdown in a controlled manner, such as
during an auxiliary blower control fault, the auxiliary blower DC link may remain energized for an extended
period of time.

Always check for presence of voltage on the auxiliary blower control DC link before servicing this
equipment. Auxiliary DC link charged indicating lights are provided on the top of the control capacitor
panel for visual indication. It is recommended that the auxiliary DC link be measured by separate
instrumentation as well before proceeding with maintenance or troubleshooting activities. Failure to do so
may result in personnel injury or death.

The auxiliary blower control speed command (AUXCMD) and the auxiliary blower speed feedback (AUXFB) can
be monitored through the PSC − Real Time Data screen. Perform the following to view:

1. Connect the PTU to the PSC panel (port is located on a bracket under the center dashboard), start the GE OHV
wPTUt Toolbox, enter password, select PSC Panel, select appropriate truck type, and click on LOGIN to
wPTUt Toolbox.
2. From the window browser, select PTU Screens −> PSC −> Normal_Operation −> Real_Time −> Real Time
Data (Figure 39).
3. The Real Time Data screen is now displayed and the auxiliary blower command and feedback can be viewed
(Figure 41).
AUXOK highlighted on the PSC − Real Time Data screen is an indication that the auxiliary blower control
system is functioning properly while it is being commanded to run the auxiliary blower.
When the auxiliary blower control system is not commanded to operate the blower, AUXOK will not be
highlighted on the PSC − Real Time Data screen.
4. Close the PSC − Real time Data display screen by clicking on the X in the upper right corner of the screen.

5. 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.

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. 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).
2. Enter an applicable password.
3. Select the appropriate GE configuration file for the truck (refer to Figure 22 for typical View Configuration
Files screen example and refer to TABLE 1 for description of files).
4. 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.

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

4.1. GE CONFIGURATION FILENAME DESCRIPTION

Configuration filenames are established using a specific set of guidelines. Each element in a filename represents a
piece of information which describes the application, revision, issue date, etc. (Figure 19).

4.2. VIEW TRUCK CONFIGURATION SCREEN

To view the Truck Configuration screen, from the window browser, select PTU Screens −> ConFigure−> Truck
Configuration.

Close the Truck Configuration display screen by clicking on the X in the upper right corner of the screen.

4.3. GE/OEM DEFAULT CONFIGURATION FILES

There are 20 default GE configuration files for the OHV AC propulsion system. They are described in TABLE 1,
Default Configuration Files and Descriptions.

NOTE: Files that apply to 320 ton vehicles are shaded. Files 1 − 13 are not included in Version 20 and later.

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 an AC truck of the following type:
S 930E − standard with DDC 4000
S 930E − standard with Cummins QSK60
The OEM configuration files would be as shown in Figure 20.

A27005A.903

A27 005 A 9 03

A27 = AC 2700 HP OHV Object Code

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

Configuration Configuration File

File Number Revision Designation
E−44425B

Figure 19. Composition of a GE AC OHV Configuration Filename.

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 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

GE default file for standard GE default file for standard

GE Defaults 930E with DDC4000: 930E with QSK60:
A32001a.210 A32002a.210

OEM file with OEM options OEM file with OEM options
OEM Files and mine information set: and mine information set:
OEM006a.210 OEM012a.210
E−45286A

Figure 20. OEM Configuration File Tree (Typical).

TABLE 1. DEFAULT CONFIGURATION FILES AND DESCRIPTIONS

GE Standard Filename Notes Description
GE240AC − 240 Ton AC (KG535xx)
A32001a.21 Standard GE320AC for KAC 930E−AC
A32001a.21 Oil Sands GE320AC for KAC 930E−AC
A32001a.21 Chuqui GE320AC for KAC 930E−AC

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 24 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 20, the features shown in TABLE 2, GE/OEM Configuration Options and Descriptions, are
available as GE/OEM configurable options. Default settings are noted.

TABLE 2. GE/OEM CONFIGURATION OPTIONS AND DESCRIPTIONS

# OPTION NAME DESCRIPTION DEFAULT
OEM Output FET Options
1 OEM Speed Option 1 Sets the speed at which Digital Output #6 (TCI) is 10 mph
energized. The digital output signal is intended to be wired
to an external light to give indication of truck speed.
2 OEM Speed Option 2 Sets the speed at which Digital Output #6 (TCI) is 25 mph
energized. The digital output signal is intended to be wired
to an external light to give indication of truck speed.
3 Engine OEM speed option Sets the speed at which Digital Output #22 (TCI) is 1700 rpm
energized. The digital output signal can be used to drive
other OEM devices based on engine speed.

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

TABLE 2. (Cont’d) GE/OEM CONFIGURATION OPTIONS AND DESCRIPTIONS

# OPTION NAME DESCRIPTION DEFAULT
Dump Body UP Speed Options
4 Dump Body UP Speed Limit Sets the speed limit applied to truck while dump body is 5 mph
UP.
5 Dump Body UP Speed Limit Sets the speed limit applied to truck while dump body is 15 mph
(With Override) UP and the Override button is pressed.
6 Dump Body UP RETARD Allows full speed control (PROPEL and RETARD effort 1 = Enabled
Enable At Max Speed modulation) at the maximum dump body UP speed. If
disabled, RETARD is not automatically applied, only
PROPEL effort is removed.
Add−On Options
7 Hydraulic Brake Outlet Enables monitoring of the hydraulic brake outlet cooling 0 = Disabled
Temp Monitor temperatures on a KMS 930E truck. To enable this option
an updated FB160 card and the additional hydraulic
sensors must be installed.
8 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.
9 Autonomous Mode Option to configure GE Drive system for Autonomous 0 = Disabled
operation in conjunction with OEM supplied equipment.
10 Axle Box Sensor Type Option to set which type of axle box pressure sensor is 0 = None
present in the system. Set to 1 if an analog sensor is 1 = Analog
installed. Set to 2 if a digital sensor is installed. Without
the option turned on, the propulsion system is unable to 2 = Digital
detect a loss of cooling air to the traction motors.
11 Auxiliary Blower Type Option to set which type of Auxiliary Cooling system is 0 = Aux Inv
present on the truck. Set to 0 if an Auxiliary Inverter 1 = Alt Blwr
system is present. Set to 1 if an Alternator Blower system
(GTA−39, GTA−41) is present. Set to 3 is a combination 2 = Hydraulic
Alternator Blower and Hydraulic Blower are present.
12 VHMS System Present Option to indicate that the KAC Vehicle Health Monitoring 0 = Not Pres.
System (VHMS) system is installed on the truck.
13 Engine Load Signal Option to set which type of engine load signal is present. Configuration
Set to 0 if the 0 to 10 volt analog system is present. Set to Dependant
21 if the Engine Speed System is used. Set to 2 if the
PWM signal is present.
14 Control Group Pressure Option to enable the use of a Control Group Blower 0 = Not
Sensor pressure Sensor. Present

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Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

TABLE 2. (Cont’d) GE/OEM CONFIGURATION OPTIONS AND DESCRIPTIONS

# OPTION NAME DESCRIPTION DEFAULT
Protection Options
15 Engine Cranking Protection Enables the engine cranking protection strategy, (i.e. 30 0 = Disabled
Enabled second max crank time, cool−down periods, etc.).
NOTE: This option should only be enabled on trucks
with an MTU or DDC engine. The Cummins QSK60
engine has a pre−lube feature which requires
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.
16 RP1 Hold−In Strategy Flag to indicate which RP1 Hold−In strategy to use. The 1 = RETARD
RP1 Hold−In feature reduces the cycles during RETARD
and helps reduce both RP1 and GY−19 grid blower motor
life. The three options are:
0 = None
1 = RETARD Mode
2 = READY Mode
Engine Warm−Up Options
17 Engine Warm−Up Mode Enables the Engine Warm−Up Mode. 0 = Disabled
18 Engine Warm−Up Speed Engine speed setting to use during Engine Warm−Up 1200 RPM
Mode.
Overloaded Options
19 Overload Response Option to set the propulsion system response to an 0 = No Resp.
overloaded truck.
0 = No response (Statistic Only)
1 = Speed Limited
2 = No Propel
20 Overloaded Sense Indicates the sense of the overload digital input. 1 = 24 V
0 = 0 V indicates active
1 = 24 V indicates active
Other Options
21 DID − LINK ON Min Engine Option to allow the Minimum engine speed with the DC 0 = Disabled
Speed Link energized to be entered via the DID panel. This
allows individual truck adjustment. This option is meant
for high altitude operation where engines have low HP at
lower RPM’s in situations such as bed raising.
22 Mine Adjustable Speed Limit Enables Mine Settable Over−speed Limits 1 = Enabled
23 Spanish Option on DID Option to enable the Spanish language support on the DID 1 = Enabled
Panel panel (Option Disabled will hide the ESPANOL key)

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

TABLE 2. (Cont’d) GE/OEM CONFIGURATION OPTIONS AND DESCRIPTIONS

# OPTION NAME DESCRIPTION DEFAULT
Other Options − (Cont’d)
24 GE Lockout Option Specialized GE Option. 0 = Disabled
25 930E−3SE Engine Speed Option to adjust Engine Speed on 3500HP systems to 0 = Disabled
Option allow for additional Cooling.
Wheel Motor Options
26 Left Wheel Motor Type Flag to indicate the wheel motor type of the Left (Driver Configuration
side) wheel. Dependent
1 = 5GDY85 A or B
2 = 5GDY85C
3 = 5GDY85D
4 = GDY85E
5 = 5GDY85 F or J
11 = 5GDY106A
21 = GEB23 A or B
22 = GEB23 C or E
31 = GEB25A
32 = GEB25B
41 = 5GDY108A
42 = 5GDY108B
51 = GEB25B
52 − GEB25B
27 Right Wheel Motor Type Flag to indicate the wheel motor type of the right Configuration
(passenger side) wheel. (Refer to selections for Option Dependent
21.)
Horsepower
28 Engine Gross HP Indicates the GHP rating of the installed diesel engine. Configuration
Dependant

4.5. SAVING NEW CONFIGURATION FILES

The activated specific options define the OEM configuration and are normally saved under a filename 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 filename.

Click on File −> Save As to save the new configuration (changes) as a new file and retain the existing configuration
of the original filename.

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 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

Verify that the desired filename is displayed. Note that the name of the file that was chosen as the valid truck
configuration is displayed automatically. A new filename is entered by typing the entire new filename. Refer back to
Figure 19 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 (Figure 22) 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 (Figure 22) in the Source Directory menu. All configuration files that are available for retrieval and
manipulation are in this directory.

To change from Source Directory to Destination Directory, proceed as follows:

1. Click on the Browse button next to the Source Directory menu.

2. Highlight the Truck folder.
3. Click on Open Directory.

To change from Destination Directory to Source Directory, proceed as follows:

1. Click on the Browse button next to the Source Directory menu.

2. Scroll up (Up Arrow) to ACConfigFiles.
3. Highlight the ACConfigFiles.
4. Click on Open Directory.

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

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 Park Brake applied and the propulsion
system placed in REST mode. Failure to do so could result in personal injury or death, as well as
equipment damage and inadvertent truck movement.

Before new software can be loaded into a truck’s propulsion system, configuration files must be created and
truck−specific parameters must be recorded. The following tasks must be completed in the order listed:

1. Select a GE Configuration file

2. Create a GE/OEM Options file
3. Save existing truck data (if applicable)
4. Program the TCI, PSC, and Inverters
5. Checkout to verify proper software installation

NOTE: The OEM file only needs to be created one time. A truck−specific 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)
(Figure 21).

E−44345A

Figure 21. Open AC Configuration Tool Sequence.

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Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

b. Select the appropriate GE configuration file for the truck (refer to Figure 22 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 (Figure
23).
2. Set the appropriate GE/OEM options for the mine location.
a. From the PTU Screens −> Configuration Browser, select Set GE/OEM Options.

E−44347A

Figure 22. View Configuration Files Screen Example.

31
GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

E−45203B

Figure 23. PTU Screens Configuration Browser.

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 24 shows example screens.
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−46736A

Figure 24. Set GE / OEM Options Screen (Part 1 of 2).

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Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

E−46736A

Figure 24. Set GE / OEM Options Screen (Part 2 of 2).

e. Enter the number corresponding to the left wheel motor type (and press Enter) and right wheel motor type
(and press Enter), then click on the X in the upper right corner of the screen to close it (Figure 25).

f. From the PTU Screens −> Configuration Browser, select Product Service Data (Figure 26). 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, OEM002t.21 would be the OEM
configuration file that is derived from GE configuration file A24002t.21.
3. Click on the OK button to go to the PTU Screens −> Configuration Browser.
4. From the PTU Screens −> Configuration Browser, select Product Service Data.
5. The Product Service Data screen is now displayed (Figure 26).

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

E−46737B

Figure 25. Set Wheel Motor Types Screen.

E−46738A

Figure 26. GE Product Service Data Screen.

6. Input the following items in this screen and press ENTER after each change/entry: (Other values may be
known and should be inputted also.)
a. OEM Truck Serial Number
b. OEM Ship Date
c. In Service Date

34
 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

7. Close the Truck Specific Data screen by clicking on the X in the upper right corner of the screen.

8. If mine−selected 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 (Figure 27).
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.

E−46757A

Figure 27. Overspeeds Screen.

5.2. SAVE EXISTING TRUCK DATA (Not Applicable to New Trucks)

For trucks that have had previous software installed, the truck’s event and statistical data should be saved prior to
downloading new software. (Also refer to Section 3.7., CONSOLIDATED TRUCK DATA SAVE FUNCTION.)

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.
2. From the PTU Screens −> TCI screen Menu Bar, select UpLoad −> Consolidated Truck Data Save
(Figure17, also refer to GEK−91712).
3. Select All Reports, choose a Save Directory, then click on the Begin button to begin uploading (Figure 18).
4. Click on Close when the uploading is complete.
5. 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.

5.3. PROGRAM TCI

1. 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 (Figure 4).
2. From the OHV PTU Toolbox Programming Utility screen, under AC Drive Systems, ALL, select TCI
(Figure 28).

35
GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

E−44355C

Figure 28. OHV PTU Programming Utility Screen.

3. Select the appropriate configuration file from the Select Configuration File menu by clicking Browse to open
the menu, then clicking on the desired file. (Also verify that correct Object File is shown, otherwise click on
Browse and select correct file before clicking on Begin Download button.)
4. Click on the Begin Download button to start downloading and automatically open the Programming the
Panel status screen (Figure 29). 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. Click on the Exit button when the download is complete to go back to the OHV wPTUt Programming Utility
screen.
6. 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.

5.4. PROGRAM PSC

1. 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 (Figure 4).
2. From the OHV wPTUt Toolbox Programming Utility screen, under AC Drive Systems, ALL, select PSC
(Figure 28).

36
Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

E−44356B

Figure 29. Programming the Panel Status Screen.

3. Select the appropriate configuration file from the Select Configuration File menu by clicking Browse to open
the menu, then clicking on the desired file. (Also verify that correct Object File is shown, otherwise click on
Browse and select correct file before clicking on Begin Download button.)
4. Click on the Begin Download button to start downloading and automatically open the Programming the
Panel status screen (Figure 29). The OHV wPTUt Toolbox Programming Utility will automatically download
the PSC with the latest PSC 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. Click on the Exit button when the download is complete to go back to the OHV wPTUt Programming Utility
screen.
6. 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.

NOTE: Throughout the procedures in the remainder of this section, it is required that the inverters be
cutout at various times. The 17KG526 Control Group does not include Inverter Cutout switches. Change
inverter status for the different control groups where necessary as follows:
On KG498 and KG526B Control Groups, place the Inverter #1 and Inverter #2 Cutout switches in the
Down position to CUTOUT or in the Up position for NORMAL operation.
On KG526C Control Groups, use the DID panel to CUTOUT Inverter #1 and Inverter #2 or to place in
NORMAL operation. Refer to Section 8., DIAGNOSTIC INFORMATION DISPLAY (DID) PANEL.

37
GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

5.5. PROGRAM INVERTERS

1. Apply the Park Brake and place the propulsion system in REST mode by placing the Park Brake and REST
rocker switches in the ON position
2. Cutout both Inverter #1 and Inverter #2 using the proper method for the control group (KG498 or KG526).
3. Verify the link charged lights are OFF and the link is discharged.
4. Determine if the system has the original IMC 2−card inverter set with a 17FB138 card and 17FB134 card, or the
latest TMC 1–card inverter set with a 17FB172 card. If unsure, perform the following steps:
a. Open the right−most control cabinet door
b. Open the electronics panel door.
c. Verify the card names in slots 9 and 11, for an FL320 panel, or slots 11 and 12 for an FL375 panel.
d. Close the electronics panel door.
5. Connect the PTU to the Inverter #1 serial port (CNG located inside the group for 17FL375 panel or RS11
located to the right of the 17FL320 panel), start the GE OHV wPTUt Toolbox, enter password, and click on
the Program Panel button (Figure 4).
6. From the OHV wPTUt Toolbox Programming Utility screen, under AC Drive Systems, GE320AC, select
the appropriate control group (Figure 28).
7. Select the appropriate object file from the Select Object File menu by clicking Browse to open the menu, then
clicking on the desired file.
8. Click on the Begin Download button to start downloading and automatically open the Programming the
Panel status screen (Figure 29). The OHV wPTUt Toolbox Programming Utility will automatically
download the connected inverter with the chosen object 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.

9. Click on the Exit button when the download is complete to go back to the OHV wPTUt Programming Utility
screen.
10. Click on the Exit button again to go back to the GE OHV wPTUt Toolbox Login screen and disconnect the
wPTUt from the Inverter #1 serial port (CNG, 17FL375 panel or RS11 17FL320 panel).
11. Connect the wPTUt to the Inverter #2 serial port (CNH, 17FL375 panel or RS12 17FL320 panel) and repeat
steps 5 through 9 of this procedure.
12. 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 Inverter #2 serial port (CNH, 17FL375 panel or
RS12 17FL320 panel).
13. Place Inverter #1 and Inverter #2 in the NORMAL mode using the proper method for the control group (KG498
or KG526). and close the control cabinet door.

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Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

5.6. CHECKOUT

NOTE: The Truck Type, Panel Type, and GE System selections are disabled in the Normal Mode.
Procedures in this manual are written for the Offline/Training Mode. Some portions of certain
procedures will be performed automatically when in the Normal Mode.

Verify proper software installation by performing the following steps:

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.
2. From the window browser, select PTU Screens −> TCI −> Normal_Operation −> Configuration −> TCI SW
Versions.
3. The TCI SW Versions screen is now displayed (Figure 30).
4. Verify the following version information on the display screen:
TCI VER: {current version}
TRUCK TYPE: {applicable horsepower}
TRUCK ID: {current truck}
5. Close the TCI SW Versions display screen by clicking on the X in the upper right corner of the screen.
6. Verify the TCI’s time is set correctly as follows:

NOTE: The event log must be cleared before the time and date can be set.

a. From the window browser, select PTU Screens −> TCI −> Special_Tasks −> Set Time and Date.
b. The Set Time and Date screen is now displayed (Figure 31)
c. Correct the date and time setting as necessary and click on SET CLOCK to enter the changes. (Press
ENTER after each date and time entry.)
d. Close the Set Time and Date display screen by clicking on the X in the upper right corner of the screen.

E−45376

Figure 30. 320 Ton Truck TCI SW Versions Screen.

39
GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

E−44380A

Figure 31. TCI Set Time and Date Screen.

E−44367A

Figure 32. Reset and Erase TCI Events Selections.

7. Reset the TCI’s event information as follows: (Figure 32)

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.
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.

40
Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

8. Reset the TCI’s Statistical Information as follows: (Figure 33)

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.
11. From the window browser, select PTU Screens −> PSC −> Normal_Operation −> Configuration −> PSC
SW Versions.

12. The PSC SW Versions screen is now displayed (Figure 34).

13. Verify the following version information on the display screen:
PSC VER: {current version}
TRUCK TYPE: {applicable HP}
TRUCK ID: {current truck}
INV1 VER: {current version}
INV2 VER: {current version}
14. Close the PSC SW Versions display screen by clicking on the X in the upper right corner of the screen.

E−45208

Figure 33. TCI Reset Stats Screen.

41
GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

E−45209

Figure 34. PSC Software Versions Screen.

15. Reset the PSC’s event information as follows: (similar to Figure 32)
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 8.3., FAULTS DISPLAY, for DID panel faults
information).
17. From the window browser, select PTU Screens −> PSC −> Normal_Operations −> Real_Time −> PSC −
Real Time Data.
18. The PSC − Real Time Data screen is now displayed (Figure 41).
19. On the PSC − Real Time Data screen, verify the following: (The CPU cards must be reprogrammed with the
pedal percentages prior to verifying these values.)
S ACCEL−SEL = 0.00 with the Accel Pedal at rest
S ACCEL−SEL = 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 Park Brake is applied and the propulsion system placed in REST mode, and that it is safe to
remove the service brakes.
S RETRD−SEL = 0.00 with the Retard Pedal and Lever (if equipped) set to the OFF position.

42
Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

S RETRD−SEL = 1.0 with the Retard Pedal at FULL. (If a 1 pedal system, ensure the service brake is not
entered)
S RETRD−SEL = 1.0 with the Retard Lever (if equipped) at FULL and the retard pedal OFF.
20. Apply the Park Brake (if not done previously) and place the propulsion system in REST mode by placing the
Park Brake and REST rocker switches in the ON position.
21. Using the appropriate mine procedures, start the diesel engine.
22. Verify the System Mode is REST on the DID panel (refer to Section 8.2., MODES DISPLAY, for DID panel
modes information).
23. Release the Park Brake and exit REST mode by placing the Park Brake and REST rocker switches in the OFF
position, and verify the System Mode changes to TEST, then READY within one minute.
24. With the service 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). (Figure 51).
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.

43
GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

6. TRUCK STARTUP PROCEDURES

NOTE: Throughout the procedures in this section, it is required that the inverters be cutout at various
times. The 17KG526 Control Group does not include Inverter Cutout switches. Change inverter status
for the different control groups where necessary as follows:
On KG498 and KG526B Control Groups, place the Inverter #1 and Inverter #2 Cutout switches in the
Down position to CUTOUT or in the Up position for NORMAL operation.
On KG526C Control Groups, use the DID panel to CUTOUT Inverter #1 and Inverter #2 or to place in
NORMAL operation. Refer to Section 8., DIAGNOSTIC INFORMATION DISPLAY (DID) PANEL.

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 volt−ohmmeter (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.

NOTE: An analog meter should be used for link resistance checks because a digital meter may give
erroneous readings due to the high capacitance of the link.

44
 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

TABLE 3. VOM CIRCUIT AND COMPONENT VALUES

Circuit/ VOM VOM Positive VOM Negative VOM Reading VOM Reading
Component Connection Lead Lead in Ohms in Ohms
Note Connection Connection (KG498E1 (KG526 Group)
Group) (Approx.)
(Approx.)
DC Link DC+ Link Bus Cabinet Ground 2800 1185
Bar (Top Bus
Bar for KG498)
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 Cabinet Ground 2800 1185
Bar (Bus Below
DC+ for KG498)
VOM on R1 DC+ Link Bus DC− Link Bus 10000 1500
Scale to avoid Bar Bar
charging
capacitors
VOM on R1 DC− Link Bus DC+ Link Bus 5.5 5.5
Scale to avoid Bar Bar
charging
capacitors

6.1.2. Alternator Field Static Exciter (AFSE) P1 Adjustment (KG498 Only)

NOTE: AFSE P1 adjustment is not required for systems with KG526 Control Groups (FM689 AFSE exciter
panels).

1. Connect the VOM positive lead to the wiper of pot P1 on the 17FM466 AFSE panel.

2. Connect the VOM negative lead to cabinet ground.

3. Adjust Pot P1 on the 17FM466 AFSE panel for a VOM reading of 6000 ohms.

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 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, 17FL320, 17FL373, or 17FL349 electronics
panels, 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.

45
GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

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. Ensure that the Park Brake is applied and the propulsion system is placed in REST mode by placing the Park
Brake and REST rocker switches in the ON position.

2. Cutout both Inverter #1 and Inverter #2 using the proper method for the control group (KG498 or KG526).

3. Make sure engine is not running.

4. Place the GF Cutout switch, located inside the main control cabinet, in the CUTOUT (down) position.

5. Disconnect Battery Power.

6. 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
7. Disconnect all PSC panel (17FL320) or Integrated Control Panel (ICP, 17FL375) 104 pin connectors.

8. Disconnect all TCI panel (17FL349/373) connectors (if applicable).

9. Install a jumper between the positive and negative DC link bus bars in the control cabinet.

10. Disconnect the CCLR1 and CCLR2 connectors (located in the center compartment near the top of each vertical
bus bar in KG526 control groups or behind the AFSE panel in KG498 control groups).

11. Disconnect the circular connectors from all VAM’s and disconnect VAM grounds (RTN62 on TB4D for KG498
control groups or VAM4 terminal VH5 for KG526 control groups).

12. Remove all wires from ground block GNDB (located to the left for both control groups).

13. On KG498 Groups Only, install jumper wires between the following cables connection points on the auxiliary
inverter:
AXSNB−1 to AM1
AXSNB−2 to AM2
AXSNB−3 to AM3
14. Remove the GF contactor arc chute and install a jumper between the main contactor tips on GF.

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. Main Power Circuit

1. Install a jumper from the GF main contactor tip to ground.

46
 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

2. 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 (typical reading is 11 megohm).

3. Turn off and disconnect the megger.

WARNING: The DC link will hold a capacitor charge after megger testing the main power circuit. Allow
sufficient time for it to discharge.

6.2.2.2. Alternator Field Circuit

1. Remove the jumper from the GF main contactor tip to ground.

2. Install a jumper from the power circuit DC positive bus bar to ground.

3. 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 at least two megohm (typical reading is infinity).

4. Turn off and disconnect the megger.

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, refer to 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. Remove the jumper wire between the GF contactor tips and reinstall the GF contactor arc chute.

2. Remove the jumper wire from the power circuit DC positive bus bar to ground.

3. Remove the jumper wire between the positive and negative DC link bus bars.

4. On KG498 Groups Only, remove the auxiliary inverter jumper wires.

5. Reconnect all wires previously removed from ground block GNDB.

6. Reconnect the VAM connectors.

7. Reconnect the CCLR1 and CCLR2 connectors.

8. Reconnect all PSC (17FL320) or ICP (17FL375) connectors.

9. Reconnect all TCI (17FL349/373) connectors (if applicable).

10. Reconnect the power plug to all phase and chopper modules.

11. Reconnect Battery Power.

47
GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

6.3. TROUBLESHOOTING FOR GROUNDS

1. Give the truck a quick visual inspection looking for the following:

a. Moisture, 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. Frayed 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.

3. Once the ground has been isolated to a particular loop, that loop should be broken down into smaller sections
and remeggered.

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.

5. Perform a vigorous inspection of the unit following the guidelines of the inspection made in step 1.

6. 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.

7. If the ground is isolated to the Dynamic Retarding Assembly, disconnect all cables leading to it and remegger
the Dynamic Retarding Assembly.

8. 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.

9. 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.

10. ,If the ground occurs on the blower motor side of the Dynamic Retarding Assembly, 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.

6.4. LOW VOLTAGE POWER SUPPLY CHECKS

NOTE: 17KG498E1 and all 17KG526 control groups have only the System Power Supply (17FH41).
Earlier versions of the 17KG498 control groups have the 17FH36 Sensor Power Supply (SPS) and either
one or two FB127 Electronics Panel Power Supplies (located in slot #1 of the 17FL electronics panels).

48
 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

6.4.1. Preparation for Power Supply Check

1. Remove the 50 amp control circuit system fuse (BATFU) located near the bottom of the power section of the
control cabinet behind the left door.

2. Disconnect all of the PSC (17FL320), TCI (17FL349/373), or ICP (17FL375) 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. Battery
1. 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).

2. Turn the truck battery switch OFF and reinstall the BATFU fuse.

3. Turn the battery switches and the key switch in the operator’s cab ON to enable control power availability to the
AC OHV propulsion system.

6.4.2.2. Electronic Panel Power Supply (If Applicable, Early KG498 Groups
Only)
1. Turn the Control Power Switch (CPS) ON (located on the side of the main control cabinet).

2. Check for +15V from TB5−A (wire number P15VDC02) to cabinet ground to verify presence of PSC +15V
power supply.

3. Check for −15V from TB5−C (wire number N15VDC02) to cabinet ground to verify presence of PSC −15V
power supply.

4. Check for +15V from TB29 (wire number 15PV) in the control cabinet where TCI is located to ground to verify
presence of source voltage for pot ref. On systems equipped with 17FL349 TCI panels, this voltage is provided
by the TCI Power Supply Card. On systems equipped with 17FL373 TCI panels, this voltage is provided by the
PSC Power Supply Card.

5. Check for +15V from TB21 (wire number 15V) to ground in the auxiliary cabinet to verify presence of power
supply voltage for gauges. On systems equipped with 17FL349 TCI panels, this voltage is provided by the TCI
Power Supply card. On systems equipped with 17FL373 TCI panels, this voltage is provided by the PSC
Power Supply Card.

6. Check for +11V (approximately) from TB28 (wire number 10V) in the control cabinet where TCI is located to
ground. On systems equipped with 17FL349 TCI panels, this voltage is provided by the TCI Power Supply
Card. On systems equipped with 17FL373 TCI panels, this voltage is provided by the PSC Power Supply Card.

49
GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

6.4.2.3. System Power Supply (If Applicable, Late KG498 and All KG526
Groups)
1. Turn the Control Power Switch ON (CPS, located in the switch panel on the outside right of the main control
cabinet).

2. On the FH41 Power Supply (located in control area of cabinet left of the ICP panel), view the green status
LEDs. Verify that all five LEDs (+15V, −15V, +5V, +24V, −24V) are illuminated.

6.4.2.4. Sensor Power Supply (If Applicable, Early KG498 Groups Only)

NOTE: Sensor Power Supply (FH36) and FB127 have now been replaced by the FH41 Power Supply.

If the Sensor Power Supply (SPS) is experiencing problems, then check the following voltages referenced to
cabinet ground:

SPS Terminal Associated Wire Nominal Voltage

Number
V+ P24VDC19 +24.4
VR+ RTN58 0.0
S+ P24VDC14 +24.4
RS+ RTN57 0.0
S− N24VDC14 −24.4
V− N24VDC19 −24.4
VR− RTN60 0.0

If a reading is significantly different from the nominal values above, check the input wiring to the SPS. If the wiring
input checks OK, then replace the SPS.

NOTE: A failed LEM could cause a low output voltage.

6.4.2.5. DID Power

Check that the DID panel is illuminated and shows DISPLAY IS READY message.

6.5. PSC AND TCI CARD CHECKS

1. Turn the CPS OFF.

2. Verify that all PSC (17FL320), TCI (17FL349/373), or ICP (17FL375) cards are properly installed and
connected to the backplane of the panel.

3. 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.

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 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

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.

6.6. LOAD AC OHV PROPULSION SYSTEM SOFTWARE

Refer to Section 5., 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 PSC−controlled outputs and PSC−monitored inputs to
verify proper wiring and component operation:

1. Apply the Park Brake and place the propulsion system in REST mode by placing the Park Brake and REST
rocker switches in the ON position.

2. Ensure engine is OFF.

3. 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.
4. From the window browser, select PTU Screens −> PSC −> Engine_Stopped_Tasks −> PSC Manual Test
(Figure 35).
5. The PSC Manual Test screen is now displayed (Figure 36).

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 (GF Cutout Switch
must be in the NORMAL position). 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.

E−45224

Figure 35. PTU Browser PSC Manual Test Screen

Access Sequence.

51
GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

E−44402A

Figure 36. PSC Manual Test Screen.

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 RP2 to highlight it. Verify that the RP2 contactor picks up and that
RP2FB is highlighted in the DI section of this screen. Click on RP2 again in the TDO section of the screen to
deenergize RP2.

e. On KG498 Groups Only, in the TDO section of the screen, click on RP3 to highlight it. Verify that the RP3
contactor picks up and that RP3FB is highlighted in the DI section of this screen. Click on RP3 again in the
TDO section of the screen to deenergize RP3.

f. In the TDO section of the screen, click on AFSE to highlight it. Verify that there is 24V DC to ground on the
AFSEL wire to ground (+25 on the GFM). Click on AFSE again in the TDO section of the screen to
deenergize AFSE.

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Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

WARNING: When viewed under some conditions, the optical port may expose the eye beyond the
maximum permissible exposure recommended in ANSI z136.2, 1993.

g. In the TDO section of the screen, click on GD1E to highlight it. Verify that the red LED (on the gray
fiber−optic port) of each module controlled by the #1 Gate Driver Power Supply is illuminated (remove the
gray plug on the top of each gate driver to observe fiber−optic light from the gate driver port). Click on GD1E
again in the TDO section of the screen to deenergize GD1E. Also check for fiber−optic light on Chopper
Module 1.

h. In the TDO section of the screen, click on GD2E to highlight it. Verify that the red LED (on the gray
fiber−optic port) of each module controlled by the #2 Gate Driver Power Supply is illuminated (remove the
gray plug on the top of each gate driver to observe fiber−optic light from the gate driver port). Click on GD2E
again in the TDO section of the screen to deenergize GD2E. Also check for fiber−optic light on Chopper
Module 2.

NOTE: All LEDs, the Inverter #1 Cutout switch, and the Inverter #2 Cutout switch are not present in the
17KG526Bx Control Group.

NOTE: Steps 6i thru 6l apply only to the 17KG498 Control Group.

i. 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.

j. 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.

k. 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.

l. 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.

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, CNXFB (KG498 Only), CNIFB, and GFNCO.

b. On KG498 and KG526C Groups Only, 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. On KG498 and KG526C Groups Only, 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 BRAKEON will be highlighted if the Service Brake is engaged, otherwise, it will be off. (To
highlight BRAKEON, turn the service brake switch ON with the engine running or apply 24 V dc to wire 44R
[TB26] with the engine OFF.)

e. Close the PSC Manual Test display screen by clicking on the X in the upper right corner of the screen.

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

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.

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. Apply control power to the AC OHV propulsion system.

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.
3. From the window browser, select PTU Screens −> TCI −> Normal_Operation −> Real_Time −> TCI Analog
Inputs (Figure 37).

E−45225

Figure 37. PTU Browser TCI Real Time Menu Access Sequence.

4. The TCI Analog Inputs screen is now displayed (Figure 38). 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 COUNTER−CLOCKWISE (typical value is 10.7
V).

f. Close the TCI Analog Inputs display screen by clicking on the X in the upper right corner of the screen.

54
Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

E−44361A

Figure 38. TCI Analog Inputs Screen.

5. 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. 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.

7. From the window browser, select PTU Screens −> PSC −> Normal_Operation −> Real_Time −> PSC −
Analog Inputs (Figure 39).

8. The PSC − Analog Inputs screen is now displayed (Figure 40). 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.

9. From the window browser, select PTU Screens −> PSC −> Normal_Operation −> Real_Time −> PSC − Real
Time Data (Figure 40).

10. The PSC − Real Time Data screen is now displayed (Figure 41). Perform the following from this screen:
a. With accel pedal FULLY RELEASED, verify that ACCEL−SEL = 0.00.
If it is not, recalibrate using the DID Panel.

55
GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

b. With accel pedal FULLY PRESSED, verify that ACCEL−SEL = 1.00.

If it is not, recalibrate using the DID Panel.
c. With retard pedal FULLY RELEASED, verify that RETRD−SEL = 0.00.
If it is not, recalibrate using the DID Panel.
d. With retard pedal FULLY PRESSED, verify that RETRD−SEL = 1.00.
If it is not, recalibrate using the DID Panel.
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.
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.

6.9. 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.

2. Download the software into the AC OHV propulsion system following those same procedures in the sections,
PROGRAM TCI and PROGRAM PSC.

E−44388B

Figure 39. PTU Browser PSC Real Time Menu Access Sequence.

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Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

E−44391A

Figure 40. PSC Analog Input Channels Screen.

3. After the new configuration has been downloaded, repeat the previous calibration checks to verify the new
settings.

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

E−44389B

Figure 41. PSC Real Time Data Screen.

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 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

6.10. 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
operator’s 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.

NOTE: The event log must be cleared before the time and date can be set.

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.
2. From the window browser, select PTU Screens −> TCI −> Special_Tasks −> Set Time and Date (Figure 42).

3. The Set Time and Date screen is now displayed (Figure 43).
4. 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.
5. On the Set Time and Date screen (Figure 43), click within the applicable window (DAY, MONTH, YEAR,
HOUR, MINUTES) and enter the new values, or highlight the existing values in the applicable window and enter
the new values.
6. Repeat step 5 for each of the five windows.
7. 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
8. Verify that the time displayed in The NEW Date and time: line is correct. If not, repeat steps 5 through 7.
9. Close the TCI Real Time Data display screen by clicking on the X in the upper right corner of the screen.
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.

E−44366A

Figure 42. PTU Browser Set Time and Date Screen Access Sequence.

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

E−45227

Figure 43. Set Time and Date Screen.

E−45231

Figure 44. Browser TCI Real Time Data Screen Access Sequence.

6.11. CHECK COMMUNICATION STATUS

The following procedure verifies that PSC and TCI are communicating properly with each other.

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.
2. From the window browser, select PTU Screens −> TCI −> Normal_Operation −> Real_Time −> TCI Real
Time Data (Figure 44).

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Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

3. The TCI Real Time Data screen is now displayed (Figure 45).

4. In the Modes section of the TCI Real Time Data screen, verify that COMMLINK is OK.
If not, check the RS422 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. Close the TCI Real Time Data display screen by clicking on the X in the upper right corner of the screen.
6. 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.
7. 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.

8. From the window browser, select PTU Screens −> PSC −> Normal_Operation −> Real_Time −> PSC − Real
Time Data (Figure 39).

9. The PSC − Real Time Data screen is now displayed (Figure 41).

10. In the Modes section of the PSC − Real Time Data screen, verify that COMMLINK is OK.

E−44359A

Figure 45. TCI Real Time Screen (Typical).

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

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.
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.

6.12. 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 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.

2. From the window browser, select PTU Screens −> TCI −> Normal_Operation −> Real_Time −> TCI Analog
Inputs (Figure 44).

3. The TCI Analog Inputs screen is now displayed (Figure 38).

4. Check the POTREF reading on the TCI Analog Inputs screen. It should be within 1.0 V of the measurement at
TB18 (wire number 10V) in the OEM cab shifter console. (Typical value is 15.0 V.)

5. Measure the voltage at TB18 (wire number 10V) in the OEM electronics cabinet. This processed Pot
Reference voltage should be approximately 11.0 V.

6. 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.

7. Check the CRANKING BATT reading on the TCI Analog Inputs screen. It should be within 1.0 V of the
measurement at TB28 (wire number 11ST) in the auxiliary cabinet.

8. Check the GROUND reading on the TCI Analog Inputs screen. It should be 0.0 V.

9. Check the GAIN CHECK reading on the TCI Analog Inputs screen. It should be 10.0 V.

NOTE: It is also recommended to check all temperature inputs and control voltages.

10. Close the TCI − Real Time Data 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 TCI serial port.

6.13. 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.

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 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

E−46750

Figure 46. PTU Browser TCI Manual Test Screen Access Sequence.

2. From the window browser, select PTU Screens −> TCI −> Engine_Stopped_Tasks −> TCI Manual Test
(Figure 46).

CAUTION: Do not proceed with TCI Manual Test checks until the Park Brake is applied (places the
propulsion system in REST mode or set the Rest Switch to REST if equipped).

3. The TCI Manual Test Truck Status screen will request truck status; verify correct status and click on OK to
proceed (Figure 47).

E−45232

Figure 47. TCI Manual Test Truck Status Screen.

4. The TCI Manual Test screen is now displayed (Figure 48).

5. With the Park Brake switch ON, measure zero volts from 52CS (TB26) to ground.

If voltages are incorrect, troubleshoot per the OEM recommendations.

NOTE: The ENGCRANK digital output is NOT enabled for manual test, since it potentially could start the
engine.

6.14. 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
(Figure 48) responds appropriately to the input from the external truck device.

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

E−46751A

Figure 48. TCI Manual Test Screen (Typical).

1. When the Lamp Test switch in the operator’s cab is activated, LAMPTEST should be displayed.

2. When the Engine System Controller issues an “Engine Caution” output, ENGCAUTION should be displayed.

3. When the Engine System Controller issues an “Engine Warning” output, ENGWARN should be displayed.

4. When the REST switch in the operator cab is placed in the ON position, RESTSW should be displayed.

5. When the Reset switch in the operator cab is actuated, RESET should be displayed.

6. When the Direction Selector handle in the operator cab is moved to the FORWARD position, FORREQ should
be displayed.

7. When the Direction Selector handle in the operator cab is moved to the REVERSE position, REVREQ should
be displayed.

8. When any Engine Shutdown switch is actuated, ENGKILL should be displayed.

9. When the Data Store switch in the operator cab is activated, DATASTORE should be displayed.

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 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

10. When the dump body is down, BODYDWN should be displayed. When the dump body is raised, BODYDWN
should no longer be displayed.

11. When the Park Brake Request switch in the operator’s cab is moved to the Request Brake position,
PRKBRKSW should be displayed.

12. When the Park Brake is applied, PRKBRKFDBK should be displayed.

13. When the Keyswitch is moved to the Engine Start position, ENGSTRTREQ should be displayed.

14. When the Retard Speed Control switch is pulled up, RSC should be displayed.

15. When the Payload Meter indicates that the truck payload is 70% of capacity or greater, MIDPAYLD should be
displayed.

16. When the Payload Meter indicates that the truck payload is 100% of capacity or greater, FULLPAYLD should
be displayed.

17. When the Payload Meter indicates that the truck payload is greater than the truck’s overload rating,
OVERPAYLD 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.

18. When the axle box is pressurized, AXLEP should be displayed (if equipped, OEM Option).

19. When the Control Power Switch is turned to the ON position, CONTROLON should be displayed.
20. Close the TCI Manual Test display screen by clicking on the X in the upper right corner of the screen.
21. 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.

6.15. 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.

6.16. INVERTER CHECKS

The following procedures verify proper inverter control operation.

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.

* Trademark of Hilgraeve Incorporated

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

6.16.1. Inverter Phase Module Command and Feedback Circuitry Checks

1. 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.

2. From the window browser, select PTU Screens −> PSC −> Normal_Operation −> Configuration −>
Inverter Parameters (Figure 49).

3. The Inverter Parameters screen is now displayed (Figure 50).

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.

5. Change the parameter by typing 0 in the Inv # all, Value field and press ENTER.
6. Close the Inverter Parameter display screen by clicking on the X in the upper right corner of the screen.
7. 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.

NOTE: In KG498 Control Groups, the CNG and CNH serial ports are located in the main control cabinet
next to the FL320 panel.

8. Disconnect the wPTUt serial cable from the PSC serial port and connect it to the CNG (Inverter #1) serial port.
9. Press T to command the Inverter Test screen.

10. Press G to command the GTO test. The screen will display the following:
gto_switch_mode[HNWX1]:

E−44387C

Figure 49. PTU Browser PSC Configuration Menu Access Sequence.

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Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

E−45234

Figure 50. Inverter Parameters Screen.

11. Press N to access the GTO/CHOPPER Test, Command and Feedback screen.

NOTE: If any the following GTO module checks fail, check GTO 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 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.

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

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 (Figure 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:
S All references to Inverter #1 are now for Inverter #2.
S All references to CNG are now for CNH.
S Shutdown the wPTUt Toolbox and turn the PTU off before disconnecting it in step 16, then do not
reconnect it.

6.17. SELF LOAD TESTING

6.17.1. Preparation for Self Load Testing

Perform the following steps prior energizing equipment for the purpose of self load testing:

1. Apply the Park Brake and place the propulsion system in REST mode by placing the Park Brake and REST
rocker switches in the ON position.

2. Cutout both Inverter #1 and Inverter #2 using the proper method for the control group (KG498 or KG526).

3. Ensure the engine is shut down and 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 (refer to Section 8.4.1., SELF
LOAD TESTING). If the DID panel is to be used, proceed to Section 6.17.2., CHECKS PRIOR TO SELF
LOAD TESTING.

4. 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.

5. From the window browser, select PTU Screens −> PSC −> Normal_Operation −> Real_Time −> PSC − Real
Time Data (Figure 39).

6. The PSC − Real Time Data screen is now displayed (Figure 41).

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 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

6.17.2. Checks Prior to Self Load Testing

6.17.2.1. 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. Verify that engine is OFF.

2. Ensure that the Park Brake is applied and the propulsion system is placed in REST mode by placing the Park
Brake and REST rocker switches in the ON position.

3. Place the GF Cutout switch, located inside the control area of the main control cabinet, in the CUTOUT (down)
position.

4. Verify that all DC link voltage indicating lights are OFF.

5. 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.

6. Close the compartment door.

7. Start the engine.

8. Place the GF Cutout switch in the NORMAL (up) position.

9. Apply the Load Brake, release the Park Brake, exit propulsion system REST mode, and note that the voltmeter
will momentarily read approximately 18 V and then drop to zero volts.

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 Park Brake and place the propulsion system in REST mode by placing the Park Brake and REST
rocker switches in the ON position.

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.

6.17.2.2. Auxiliary Blower Rotation Check (KG498 Groups Only)

1. Remove the inspection cover from the Auxiliary Blower on the Dynamic Retarding Assembly side of the truck.

2. Start the engine.

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

3. Place the GF Cutout switch in the NORMAL (up) position.

4. Exit the propulsion system REST mode by placing the REST rocker switch in the OFF position.

5. Verify that the rotation of the auxiliary blower is clockwise as viewed from the Dynamic Retarding Assembly
side of the truck.

NOTE: If the rotation is NOT as indicated above, then shutdown the drive system and the engine in the
normal manner. After verifying that ALL power is removed from BOTH the main propulsion and auxiliary
blower inverter DC links, switch two of the power leads to the auxiliary blower motor and repeat this
complete procedure.

6. Place the propulsion system in the REST mode by placing the REST rocker switch in the ON position.

7. Place the GF Cutout switch in the CUTOUT (down) position.

8. Shut down the engine.

9. Re−install the auxiliary blower inspection cover.

10. Start the engine.

11. Place the GF Cutout switch in the NORMAL (up) position.

12. Exit the propulsion system REST mode by placing the REST rocker switch in the OFF position.

13. With the direction selector switch in NEUTRAL, depress the accel pedal fully in order to increase the speed of
the auxiliary blower. Verify on the PSC − Real Time Data screen that the AUXCMD and AUXFB both reach
3600 RPM (Figure 41).

6.17.3. Self Load Test Procedure

After the procedures in Section 6.17.1., PREPARATION FOR SELF LOAD TESTING and Section 6.17.2.,
CHECKS PRIOR TO SELF LOAD TESTING have been completed successfully, conduct the Self Load Test as
follows:

1. Verify that the Direction Selector handle is in the NEUTRAL position.

2. Ensure that the Park Brake is applied and the propulsion system is placed in REST mode by placing the Park
Brake and REST rocker switches in the ON position.

NOTE: Self load testing can also be commanded through the DID panel (refer to Section 8.4.1., 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. Close the PSC − Real Time Data display screen by clicking on the X in the upper right corner of the screen.

4. From the window browser, select PTU Screens −> PSC −> Normal_Operation −> Tests −> Self Load
Engine Test (Figure 39).

5. The Self Load Engine Test screen is now displayed (Figure 51).

6. Click on the ENTER LDBX button and verify on the Self Load Engine Test screen that the PSCMODE:
changes to TEST and the SUBSTATE: changes to LOADBOX before proceeding.

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Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

E−46752A

Figure 51. Self Load Engine Test Screen.

7. 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 400 (−400) or the
ENGLOAD value is 0.0%, that is an indication that the engine load signal is not being communicated to
PSC.

8. Monitor DC link parameters GFAULT and LINKV as engine loading increases. Make certain that the GFAULT
value increases as the LINKV value does. If it does not, abort the test and troubleshoot the ground fault
circuitry. (Refer to Section 6.19. FUNCTIONAL GROUND FAULT DETECTION TEST, Section 6.2. MEGGER
TEST FOR GROUNDS, and Section 6.3. TROUBLESHOOTING FOR GROUNDS for procedures.)

9. 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.

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

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.

10. When self load testing is complete, release the accelerator pedal and click on the EXIT LDBX button. Self load
testing should stop.
11. Close the Self Load Engine Test 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.

6.18. 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. Shut down 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.

3. From the window browser, select PTU Screens −> PSC −> Normal_Operation −> Real_Time −> PSC − Real
Time Data (Figure 39).

4. The PSC − Real Time Data screen is now displayed (Figure 41).

5. Place the following switches in the positions indicated:

a. Park Brake rocker switch should be ON.

b. REST mode rocker switch should be ON.

c. Inverter #2 should be CUTOUT using the proper method for the control group (KG498 or KG526).

d. Inverter #1 should be in NORMAL operating mode using the proper method for the control group (KG498 or
KG526).

6. Start the engine.

7. Release the Park Brake and exit propulsion system REST mode by placing the Park Brake and REST rocker
switches in the OFF position.

CAUTION: Do not accelerate the wheel motors if the truck is on jack stands.

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Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

8. Place the Direction Selector handle 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 ft−lbs. 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.

10. Place the Direction Selector handle in the NEUTRAL position.

11. Apply the Park Brake and place the propulsion system in REST mode by placing the Park Brake and REST
rocker switches in the ON position.

12. Repeat steps 5 through 10 for Inverter #2 (with Inverter #2 placed in NORMAL operating mode and Inverter #1
CUTOUT using the proper method for the control group, KG498 or KG526, 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 Park Brake and place the propulsion system in REST mode, place Inverter #1 and Inverter #2 in the
NORMAL operating mode using the proper method for the control group (KG498 or KG526), then release the
Park Brake and exit propulsion system 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 handle in FORWARD −

(1) Left wheel motor − counterclockwise rotation

(2) Right wheel motor − clockwise rotation

b. Direction Selector handle in REVERSE −

(1) Left wheel motor − clockwise rotation

(2) Right wheel motor − counterclockwise 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.

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

15. When inverter testing is complete, move the Direction Selector handle to the NEUTRAL position, apply the
Park Brake and place the propulsion system in REST mode by placing the Park Brake and REST rocker
switches in the ON position, cut out both Inverter #1 and Inverter #2 using the proper method for the control
group (KG498 or KG526), and shut down the engine.

6.19. 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.

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 procedure test the ground fault circuit using the Self Load Testing (Section 6.17.) procedure.

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 Park Brake is ON, propulsion system is in
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.

1. Install a test wire jumper between the DC bus and a ground point in a convenient location (refer to WARNING
above).

2. Start the engine.

3. Perform steps 1 − 8 of the procedure in Section 6.17.3., SELF LOAD TEST PROCEDURE.

4. A ground fault event with accompanying loss of propel should be generated shortly after the RP1 contactor
closes.

5. If a fault event is not generated, abort the test and troubleshoot the ground fault circuitry. (Refer to Section 6.2.
MEGGER TEST FOR GROUNDS and Section 6.3. TROUBLESHOOTING FOR GROUNDS for procedures.)

6. Shut down the engine and remove the test wire jumper (refer to WARNING above).

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 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

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 4, 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 4) and Profiles (TABLE 5, 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 last−fiscal−quarter, also
known as the last−three−months. This counter has the same value in it all quarter long. At midnight on a quarter
change, this counter is overwritten by the “This Qtr” value as this−quarter becomes last−quarter.

The third counter, This Qtr, keeps a moment by moment count of occurrences of the parameter. The counts are
not reset to zero until midnight of the next quarter.

The fourth counter, Last Mnth, keeps a moment by moment count of occurrences of the parameter over the last
month. 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 this−month becomes last−month.

The fifth counter, This Mnth, keeps a moment by moment count of occurrences of the parameter just as This Qtr,
except the This Mnth count is reset to zero at midnight of the next month.

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

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 this−day becomes yesterday.

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 3.7., CONSOLIDATED TRUCK DATA SAVE FUNCTION, for procedures.

The wPTUt provides the capability to view the current values of the statistical counters 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.
2. From the window browser, select PTU Screens −> TCI −> Special_tasks −> Stat_Menu −> View Counters
(Figure 52).
3. The View Counters screen is now displayed (Figure 53).
4. Select the COUNTER Group to view from the menu on the screen, then click on View Counter Group.

E−46753

Figure 52. TCI Stat_Menu Selections.

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Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

E−45211

Figure 53. View Counters Screen Example.

5. The Mine Counters screen displaying the selected COUNTER Group is now displayed (Figure 54).
6. Close the Mine Counters display screen by clicking on the X in the upper right corner of the screen.
7. 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.
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.

E−45212

Figure 54. Mine Counters Screen (PSC_STATS).

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

7.3. VIEW STATISTICAL PROFILES

NOTE: It may be desirable to upload Statistical Profiles to a PC for later viewing/analysis. Refer to
Section 3.7., CONSOLIDATED TRUCK DATA SAVE FUNCTION, for procedures.

The wPTUt provides the capability to view the current values of the statistical profiles 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.
2. From the window browser, select PTU Screens −> TCI −> Special_tasks −> Stat_Menu −> View Profiles
(Figure 52).
3. The View Mine Profiles screen is now displayed (Figure 55).
4. Select the profile to view from the SELECT PROFILE TO VIEW menu on the screen, then click on VIEW
PROFILES.
5. The Mine Profiles screen displaying the selected profile is now displayed (Figure 56).
6. Close the Mine Profiles display screen by clicking on the X in the upper right corner of the screen.
7. 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.
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.

E−45213

Figure 55. View Profiles Screen Example.

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 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

E−45214

Figure 56. Mine Profiles Screen (PSC_STATS).

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
3.7., CONSOLIDATED TRUCK DATA SAVE FUNCTION, for procedures.

The wPTUt Toolbox provides the capability to view the truck serial and configuration report 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.
2. From the window browser, select PTU Screens −> TCI −> Special_tasks −> Stat_Menu −> Serial−Cfg
Report (Figure 52).
3. The Serial−Cfg Report screen displaying the Serial & Configuration Report is now displayed (Figure 57).
4. Close the Serial−Cfg Report display screen by clicking on the X in the upper right corner of the screen.
5. 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.

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

E−45219A

Figure 57. Stat Serial Report Screen.

2. From the window browser, select PTU Screens −> TCI −> Special_tasks −> Stat_Menu −> Reset Stats
(Figure 52).
3. The Reset Stats screen displaying the Stat Reset Menu is now displayed (Figure 58).
4. Reset the desired stat (or stats) on the Reset Stats screen using the following methods:
S Enter the counter to be reset in the RESET Individual COUNTER box and click on RESET Individual
COUNTER to perform the reset.
S Enter the profile to be reset in the Or, Enter Profile box and click on Or, Enter Profile to perform the reset.
S 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 (Figure
59). Close either display screen by clicking on the X in the upper right corner of the screen.
S 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 (Figure 60).
5. Close the Reset Stats display screen by clicking on the X in the upper right corner of the screen.
6. 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.

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Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

E−45220A

Figure 58. Reset Stats Screen.

E−45221

Figure 59. Stat Profile Mine Reset Screen.

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

E−45223

Figure 60. Reset Box Question Selection Screens.

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 3.7., CONSOLIDATED TRUCK DATA SAVE FUNCTION.

To upload statistical data, do the following:

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.
2. From the PTU Screens −> TCI screen Menu Bar, select UpLoad −> Consolidated Truck Data Save
(Figure17, refer to GEK−91712).

NOTE: Files are normally uploaded to the following:

c:/program files/geohvptu_xx/data_ac/<truck id date time>

3. 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 (Figure 18).
4. 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.
5. Close the wPTUt Toolbox, shut down the PTU, and disconnect it from the TCI serial port.

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Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

TABLE 4. STATISTICAL DATA CODES − COUNTERS

Cntr. No. Description Units Count Conditions
301 Truck Life Hours 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 non−zero values in the
Lifetime Counter column.
302 Control Power On Hours The number of hours that the control power relay (CPR) has
been energized.
303 Engine Operate Hours The number of hours of engine operation above the engine
running threshold criteria.
304 Engine Idle Hours The number of hours when engine is idling and truck is
stationary.
305 Truck Operate Hours The summation of the number of hours that the propulsion
system has operated in propulsion, retard, ready and test.
306 Truck Parked Hours The number of hours that the Park Brake applied feedback is
true while TCI is energized.
307 Truck Travel Miles The cumulative miles travelled 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.
308 Truck Travel Kilometers 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.
309 Wheel 1 Operate Hours The number of hours that wheel #1 was providing torque in
either propulsion or retard, and was moving.
310 Wheel 2 Operate Hours The number of hours that wheel #2 was providing torque in
either propulsion or retard, and was moving.
311 Propel Forward Hours The number of hours that the truck was moving forward in
the propulsion mode of operation.
312 Retard Forward Hours The number of hours that the truck was moving forward in
the retard mode of operation.
313 Propel Mode Hours The number of hours that the truck was moving in the
propulsion mode of operation.
314 Retard Mode Hours The number of hours that the truck was moving in the retard
mode of operation.
315 CPR Pickup Occurrences The number of times when the Keyswitch was moved from
the STOP to the ON position.
316 GF Pickup Occurrences The number of times that the GF contactor feedback has
changed from deenergized to energized indication.
317 GFR Pickup Occurrences The number of times that the GFR relay feedback has
changed from deenergized to energized indication.
318 RP1 Pickup Occurrences The number of times that the RP1 contactor feedback has
changed from deenergized to energized indication.

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TABLE 4. (Cont’d) STATISTICAL DATA CODES − COUNTERS

Cntr. No. Description Units Count Conditions
319 RP2 Pickup Occurrences The number of times that the RP2 contactor feedback has
changed from deenergized to energized indication.
320 RP3 Pickup Occurrences The number of times that the RP3 contactor feedback has
changed from deenergized to energized indication.
321 Dump Body Up Occurrences The number of times that the Dump Body position sensor
input has changed from true to false, indicating that the dump
body has been raised.
322 Loaded Truck Occurrences The number of times that the Full Payload input has changed
from false to true.
323 Speed Set 1 Occurrences The number of times that the programmable speed set point
#1 has been exceeded.
324 Speed Set 2 Occurrences The number of times that the programmable speed set point
#2 has been exceeded.
325 Engine Start Switch Occurrences The number of times that the engine start request was
actuated by the operator’s Keyswitch.
326 Engine On & Start Occurrences The number of times that engine start request received while
the engine above its running threshold criteria.
327 Separate Batteries Occurrences The number of times that the control and cranking batteries
were commanded to separate.
328 Engine Crank Occurrences The number of times that a crank command has been issued
to the engine.
329 Engine Starts Occurrences The number of times that the measured engine speed has
exceeded the engine running criteria.
330 Engine Off Occurrences The number of times that the Engine Kill pushbutton was
actuated.
331 Park Brake Request Occurrences The number of times that the Park Brake switch was
actuated.
332 Park Brake Applied Occurrences The number of times that the Park Brake pressure switch
feedback transitioned from false to true, indicating that the
Park Brake was applied.
333 SS to Reverse Occurrences The number of times that the Direction Selector switch was
moved to the Reverse position.
334 SS to Forward Occurrences The number of times that the Direction Selector switch was
moved to the Forward position.
335 SS When Moving Occurrences The number of times that the Direction Selector switch was
moved to command a change in direction while the truck was
moving.
336 RSC Switch On Occurrences The number of times that the Retard Speed Control switch was
moved from Off to On.
337 Rest Request Occurrences The number of times that the rest request was received by
actuation of the Rest Request switch.

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TABLE 4. (Cont’d) STATISTICAL DATA CODES − COUNTERS

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

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TABLE 4. (Cont’d) STATISTICAL DATA CODES − COUNTERS

Cntr. No. Description Units Count Conditions
362 M2 Spin Count Occurrences The number of times that Wheel #2 Spin Control is
activated.
363 M2 Slide Count Occurrences The number of times that Wheel #2 Slide Control is
activated.
364 Service Brake Time Seconds The number of seconds that the wet brake is applied and
truck speed is > no motion speed.
365 Service Brake App Occurrences The number of times that the wet brake is applied and truck
speed is > no motion speed.
366 Load Box Mode Seconds The number of seconds that the system is in load box mode.
367 Batt Chrg Fail Seconds Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
368 Pedal Calibrat Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
369 Pedal Failures Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
Note: Parameter Numbers 1000 through 1099 correspond to DID Panel PSC Events 000 through 099,
respectively (shown on DID panel and wPTUt Toolbox).
1000 spare
1001 spare
1002 Ground Fault Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1003 Failed Diode Panel Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1004 GFCO Not Reset Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1005 Propulsion System Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
Over Temp DESCRIPTIONS
1006 Both Inv Comms Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
Failed DESCRIPTIONS
1007 spare
1008 DC Link Over Volt Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1009 ALTF Over Amps Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1010 spare
1011 Retard Lever Signal Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1012 Retard Pedal Signal Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS

86
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TABLE 4. (Cont’d) STATISTICAL DATA CODES − COUNTERS

Cntr. No. Description Units Count Conditions
1013 Mid V Failure Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1014 Analog Sensor Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
Faults DESCRIPTIONS
1015 Restrictive Analog Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
Sensor Fault DESCRIPTIONS
1016 PSC CPU Card Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
Fault DESCRIPTIONS
1017 FB104 Digital Card Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1018 FB143 Analog Card Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1019 Riding Retard Pedal Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1020 High Torque Limit Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1021 TCI Comm Fault Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1022 Persistent TCI Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
Comm Fault DESCRIPTIONS
1023 Tertiary Overcurrent Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1024 CFG File Error Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1025 Blower Fault Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1026 Cap Overpressure Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1027 Panel Not Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
Connected at Power DESCRIPTIONS
Up
1028 spare
1029 spare
1030 GF Contactor Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1031 Battery Boost Circuit Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1032 RP Contactors Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1033 RP−HP Balance Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS

87
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TABLE 4. (Cont’d) STATISTICAL DATA CODES − COUNTERS

Cntr. No. Description Units Count Conditions
1034 spare
1035 ESS Input Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1036 Grid Blower Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1037 Computer Power Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
Supply DESCRIPTIONS
1038 spare
1039 spare
1040 24V Positive Bad Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1041 24V Negative Bad Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1042 Self Load & Dir Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1043 Battery Volt Low Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1044 Battery Volt High Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1045 Chopper Open Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
Circuit DESCRIPTIONS
1046 Retard Circuit Short Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1047 Engine Stall Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1048 Shorted DC Link Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1049 Hyb−Comm Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1050 spare
1051 Tach Left Rear Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1052 Tach Right Rear Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1053 FLeft Speed Sig Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1054 FRight Speed Sig Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1055 Front Wheel Tachs Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS

88
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TABLE 4. (Cont’d) STATISTICAL DATA CODES − COUNTERS

Cntr. No. Description Units Count Conditions
1056 Inverter SW Version Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1057 Inv 1 SW Type Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1058 Inv 2 SW Type Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1059 spare
1060 spare
1061 Motor Over Speed Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1062 spare
1063 Engine Load Sig Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1064 spare
1065 Temp Input Bad Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1066 spare
1067 spare
1068 spare
1069 spare
1070 Link Cap Level Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
Getting Low DESCRIPTIONS
1071 Link Cap Level Too Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
Low DESCRIPTIONS
1072 Ground Fault Circuit Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
Problem DESCRIPTIONS
1073 Sensor Offset Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1074 INV1 Comm Failed Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1075 INV2 Comm Failed Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1076 FB173 Card Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1077 Inverter Failed VI Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
Test DESCRIPTIONS
1078 Inv Bkgnd Msg Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1079 FB173 NoPropel Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS

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TABLE 4. (Cont’d) STATISTICAL DATA CODES − COUNTERS

Cntr. No. Description Units Count Conditions
1080 spare
1081 spare
1082 spare
1083 spare
1084 CPS & Moving Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1085 Aux Cooling Fault Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1086 spare
1087 Engine HP Low Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1088 HP Over Limit Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1089 Engine Speed Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
Command DESCRIPTIONS
1090 spare
1091 INV1 Cutout Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1092 INV2 Cutout Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1093 spare
1094 Limp Req Error Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1095 BBRAM Error Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1096 Unexpected System Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
Reset DESCRIPTIONS
1097 spare
1098 PTU Data Store Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1099 Software Event Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
Note: Parameter Numbers 1100 through 1199 correspond to Inverter #1 Event Codes
100 through 199, respectively (shown on DID panel and wPTUt Toolbox).
1100 INV1 CPU Card Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1101 INV1 CPU NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1102 INV1 I/O Card Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS

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TABLE 4. (Cont’d) STATISTICAL DATA CODES − COUNTERS

Cntr. No. Description Units Count Conditions
1103 INV1 I/O NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1104 INV1 FO Card Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1105 INV1 PS Card Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1106 INV1 DC Power Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1107 GDPS1 Fail Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1108 spare
1109 INV1 LinkV Fail Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1110 spare
1111 INV1 Input Volt Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
Sensor DESCRIPTIONS
1112 spare
1113 INV1 General Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1114 INV1 General NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1115 INV1 System Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1116 INV1 A Phase Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1117 INV1 A+ Phase Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1118 INV1 A+ Phase NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1119 INV1 A− Phase Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1120 INV1 A− Phase NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1121 INV1 A Phase Amps Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1122 spare
1123 INV1 A Phase Volts Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1124 spare

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TABLE 4. (Cont’d) STATISTICAL DATA CODES − COUNTERS

Cntr. No. Description Units Count Conditions
1125 INV1 B Phase Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1126 INV1 B+ Phase Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1127 INV1 B+ Phase NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1128 INV1 B− Phase Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1129 INV1 B− Phase NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1130 INV1 B Phase Amps Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1131 spare
1132 INV1 B Phase Volts Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1133 spare
1134 INV1 C Phase Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1135 INV1 C+ Phase Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1136 INV1 C+ Phase NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1137 INV1 C− Phase Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1138 INV1 C− Phase NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1139 spare
1140 spare
1141 INV1 C Phase Volts Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1142 spare
1143 INV1 Tach 1 Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1144 INV1 Tach 1 NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1145 INV1 Tach 2 Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1146 INV1 Tach 2 NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1147 spare

92
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TABLE 4. (Cont’d) STATISTICAL DATA CODES − COUNTERS

Cntr. No. Description Units Count Conditions
1148 Chopper 1 NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1149 spare
1150 Chopper 2 NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1151 INV1 Misc Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1152 spare
1153 INV1 Motor Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1154 INV1 Motor Faults Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
NR DESCRIPTIONS
1155 INV1 Second Load Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
Note: Parameter Numbers 1200 through 1299 correspond to Inverter #2 Event Codes
200 through 299, respectively (shown on DID panel and wPTUt Toolbox).
1200 INV2 CPU Card Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1201 INV2 CPU NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1202 INV2 I/O Card Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1203 INV2 I/O NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1204 INV2 FO Card Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1205 INV2 PS Card Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1206 INV2 DC Power Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1207 GDPS2 Fail Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1208 spare
1209 INV2 LinkV Fail Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1210 spare
1211 INV2 Input Volt Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
Sensor DESCRIPTIONS
1212 spare

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TABLE 4. (Cont’d) STATISTICAL DATA CODES − COUNTERS

Cntr. No. Description Units Count Conditions
1213 INV2 General Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1214 INV2 General NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1215 INV2 System Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1216 INV2 A Phase Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1217 INV2 A+ Phase Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1218 INV2 A+ Phase NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1219 INV2 A− Phase Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1220 INV2 A− Phase NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1221 INV2 A Phase Amps Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1222 spare
1223 INV2 A Phase Volts Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1224 spare
1225 INV2 B Phase Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1226 INV2 B+ Phase Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1227 INV2 B+ Phase NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1228 INV2 B− Phase Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1229 INV2 B− Phase NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1230 INV2 B Phase Amps Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1231 spare
1232 INV2 B Phase Volts Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1233 spare
1234 INV2 C Phase Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS

94
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TABLE 4. (Cont’d) STATISTICAL DATA CODES − COUNTERS

Cntr. No. Description Units Count Conditions
1235 INV2 C+ Phase Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1236 INV2 C+ Phase NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1237 INV2 C− Phase Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1238 INV2 C− Phase NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1239 spare
1240 spare
1241 INV2 C Phase Volts Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1242 spare
1243 INV2 Tach 1 Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1244 INV2 Tach 1 NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1245 INV2 Tach 2 Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1246 INV2 Tach 2 NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1247 spare
1248 Chopper 1 NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1249 spare
1250 Chopper 2 NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1251 INV2 Misc Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1252 spare
1253 INV2 Motor Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1254 INV2 Motor Faults Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
NR DESCRIPTIONS
1255 INV2 Second Load Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
Note: Parameter Numbers 1600 through 1699 correspond to TCI Events 600 through 699,
respectively (shown on DID panel and wPTUt Toolbox).
1600 spare

95
GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

TABLE 4. (Cont’d) STATISTICAL DATA CODES − COUNTERS

Cntr. No. Description Units Count Conditions
1601 CPU Card Fault Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1602 FB104 Digital I/O Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1603 FB160 Analog I/O Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1604 PSC Comm Bad Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1605 Aux Comm Fault Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1606 Panel Connect Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1607 5V Positive Bad Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1608 15V Positive Bad Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1609 15V Negative Bad Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1610 Pot Ref Bad Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1611 spare
1612 spare
1613 Analog Input Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1614 BSep Cont Fail Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1615 spare
1616 Forin & Revin Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1617 Eng Start Denied Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1618 spare
1619 Engine Warning Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1620 Eng Kill & Speed Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1621 spare
1622 Park Brake Problem Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS

96
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TABLE 4. (Cont’d) STATISTICAL DATA CODES − COUNTERS

Cntr. No. Description Units Count Conditions
1623 Hyd Brake Fluid Hot Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1624 Body Up & Load Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1625 Body Up & Speed Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1626 Load Brake & Speed Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1627 spare
1628 Battery Volts Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1629 Baro Press Signal Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1630 Motor Blower Press Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1631 Amb Temp Signal Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1632 CFG File Error Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1633 BBRAM Error Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1634 Overload Restrictive Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1635 Overload NR Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1636 Aux Inverter Faults Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1637 spare
1638 Engine Crank Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
Timeout DESCRIPTIONS
1639 Engine Start Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
Request & Running DESCRIPTIONS
1640 Accel Pedal too High Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1641 Accel Pedal too Low Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1642 Crank Override Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1643 Cntrl Blower P Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS

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TABLE 4. (Cont’d) STATISTICAL DATA CODES − COUNTERS

Cntr. No. Description Units Count Conditions
1644 thru spare
1649
1650 Pedal Calibrat Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1651 Truck ID Incor Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1652 thru spare
1690
1691 spare
1692 spare
1693 spare
1694 spare
1695 spare
1696 Unexpected CPU Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
Reset DESCRIPTIONS
1697 spare
1698 Data Store Occurrences Refer to TABLE 6 OR TABLE 7 − EVENT CODE
DESCRIPTIONS
1699 spare

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7.7. PROFILE (HISTOGRAM) DEFINITIONS

The word histogram is used in the definitions of the various statistical profiles in TABLE 5. A histogram is a collec-
tion of statistical data organized into defined ranges of values. The graphical representation of a histogram is typical-
ly a bar chart.

TABLE 5. STATISTICAL DATA CODES − PROFILES

Prof. No. Description Count Conditions
401 Alt HPNET In 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 his-
togram breaks the horsepower spectrum into 17 buckets, and displays the
time that was spent in each bucket. The buckets are defined as follows:
NUMBER NET INPUT HORSEPOWER RANGE
1. 450 and below
2. 451 to 650
3. 651 to 850
4. 851 to 1050
5. 1051 to 1250
6. 1251 to 1450
7. 1451 to 1650
8. 1651 to 1850
9. 1851 to 2050
10. 2051 to 2150
11. 2151 to 2250
12. 2251 to 2350
13. 2351 to 2450
14. 2451 to 2550
15. 2551 to 2650
16. 2651 to 2750
17. 2751 and above
402 Control Battery 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 VOLTAGE RANGE
1. 12 and below
2. >12 to ≤14
3. >14 to ≤16
4. >16 to ≤18
5. >18 to ≤20
6. >20 to ≤22
7. >22 to ≤24
8. >24 to ≤26
9. >26 to ≤27
10. >27 to ≤28
11. >28 to ≤29
12. >29 to ≤30
13. >30 to ≤32
14. >32 to ≤34
15. >34 to ≤36
16. >36 to ≤38
17. 38 and above

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TABLE 5. (Cont’d) STATISTICAL DATA CODES − PROFILES

Prof. No. Description Count Conditions
403 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 VOLTAGE RANGE
1. ≤2
2. >2 to ≤4
3. >4 to ≤6
4. >6 to ≤8
5. >8 to ≤10
6. >10 to ≤12
7. >12 to ≤14
8. >14 to ≤16
9. >16 to ≤18
10. >18 to ≤20
11. >20 to ≤22
12. >22 to ≤24
13. >24 to ≤26
14. >26 to ≤28
15. >28 to ≤30
16. >30 to ≤32
17. >32
404 Spare
405 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 HORSEPOWER RANGE
1. 800 and below
2. 801 to 1200
3. 1201 to 1600
4. 1601 to 2000
5. 2001 to 2400
6. 2401 to 2800
7. 2801 to 3200
8. 3201 to 3600
9. 3601 to 3800
10. 3801 to 4000
11. 4001 to 4200
12. 4201 to 4400
13. 4401 to 4600
14. 4601 to 4800
15. 4801 to 5000
16. 5001 to 5200
17. 5201 and above
406 Spare

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TABLE 5. (Cont’d) STATISTICAL DATA CODES − PROFILES

Prof. No. Description Count Conditions
407 Truck Spd MPH 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 dis-
plays the time that was spent in each bucket. The buckets are defined as
follows:
NUMBER TRUCK SPEED RANGE (MPH)
1. 2.0 and below
2. 2.1 to 4.0
3. 4.1 to 5.0
4. 5.1 to 6.0
5. 6.1 to 8.0
6. 8.1 to 10.0
7. 10.1 to 12.0
8. 12.1 to 17.0
9. 17.1 to 22.0
10. 22.1 to 27.0
11. 27.1 to 32.0
12. 32.1 to 37.0
13. 37.1 to 39.0
14. 39.1 to 41.0
15. 41.1 to 43.0
16. 43.1 to 45.0
17. 45.1 and above
408 Truck Spd KPH 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 dis-
plays the time that was spent in each bucket. The buckets are defined as
follows:
NUMBER TRUCK SPEED RANGE (KPH)
1. 3.0 and below
2. 3.1 to 6.4
3. 6.5 to 8.0
4. 8.1 to 9.6
5. 9.7 to 12.8
6. 12.9 to 16.0
7. 16.1 to 19.0
8. 19.1 to 27.0
9. 27.1 to 35.0
10. 35.1 to 43.0
11. 43.1 to 51.0
12. 51.1 to 60.0
13. 60.1 to 63.0
14. 63.1 to 66.0
15. 66.1 to 69.0
16. 69.1 to 72.0
17. 72.1 and above

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TABLE 5. (Cont’d) STATISTICAL DATA CODES − PROFILES

Prof. No. Description Count Conditions
409 Motor 1 RPM 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 se-
cond. The histogram breaks the RPM spectrum into 17 buckets, and dis-
plays the time that was spent in each bucket. The buckets are defined as
follows:
NUMBER MOTOR 1 SPEED RANGE (RPM)
1. 70 and below
2. 71 to 287
3. 288 to 452
4. 453 to 567
5. 568 to 735
6. 736 to 900
7. 901 to 1050
8. 1051 to 1200
9. 1201 to 1500
10. 1501 to 1800
11. 1801 to 2100
12. 2101 to 2400
13. 2401 to 2700
14. 2701 to 3000
15. 3001 to 3150
16. 3151 to 3300
17. 3301 and above
410 Motor 2 RPM This is a 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 se-
cond. The histogram breaks the RPM spectrum into 17 buckets, and dis-
plays the time that was spent in each bucket. The buckets are defined as
follows:
NUMBER MOTOR 2 SPEED RANGE (RPM)
1. 70 and below
2. 71 to 287
3. 288 to 452
4. 453 to 567
5. 568 to 735
6. 736 to 900
7. 901 to 1050
8. 1051 to 1200
9. 1201 to 1500
10. 1501 to 1800
11. 1801 to 2100
12. 2101 to 2400
13. 2401 to 2700
14. 2701 to 3000
15. 3001 to 3150
16. 3151 to 3300
17. 3301 and above

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TABLE 5. (Cont’d) STATISTICAL DATA CODES − PROFILES

Prof. No. Description Count Conditions
411 Event 636 Sub−id This is a histogram of the number of times each Event 636, Aux Blower Fail-
ure, sub−ID logs. Each time the aux controller sends a 636 sub−ID the ap-
propriate bucket is incremented by 1. (Truck_type = 320 Ton AC only.)
The buckets are defined as follows:
NUMBER
1. sub−ID 1
2. sub−ID 2
3. sub−ID 3
4. sub−ID 4
5. sub−ID 5
6. sub−ID 6
7. sub−ID 7
8. sub−ID 8
9. sub−ID 9
10. sub−ID 10
11. sub−ID 11
12. sub−ID 12
13. sub−ID 13
14. sub−ID 14
15. sub−ID 15
412 Service Brakes 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. 2.0 or less
2. 2.1 to 4.0
3. 4.1 to 5.0
4. 5.1 to 6.0
5. 6.1 to 8.0
6. 8.1 to 10.0
7. 10.1 to 12.0
8. 12.1 to 17.0
9. 17.1 to 22.0
10. 22.1 to 27.0
11. 27.1 to 32.0
12. 32.1 to 37.0
13. 37.1 to 39.0
14. 39.1 to 41.0
15. 41.1 to 43.0
16. 43.1 to 45.0
17. 45.1 or greater

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TABLE 5. (Cont’d) STATISTICAL DATA CODES − PROFILES

Prof. No. Description Count Conditions
413 Ambient Temp Low This is a histogram of ambient temperature. The clock starts whenever con-
trol power (CPR) is on. Sample time is every 1.0 seconds. The histogram
breaks the temperature spectrum into 17 buckets, and displays the time that
was spent in each bucket. The buckets are defined as follows:
NUMBER TEMPERATURE RANGE (DEGREE C)
1. −40 and below
2. −39 to −30
3. −29 to −25
4. −24 to −20
5. −19 to −15
6. −14 to −10
7. −9 to −5
8. −4 to 0
9. 1 to 5
10. 6 to 10
11. 11 to 15
12. 16 to 20
13. 21 to 25
14. 26 to 30
15. 31 to 35
16. 36 to 40
17. 41 and above
414 Ambient Temp High This is a histogram of ambient temperature. The clock starts whenever con-
trol power (CPR) is on. Sample time is every 1.0 seconds. The histogram
breaks the temperature spectrum into 17 buckets, and displays the time that
was spent in each bucket. The buckets are defined as follows:
NUMBER TEMPERATURE RANGE (DEGREE C)
1. 35 and below
2. 36 to 37
3. 38 to 39
4. 40 to 41
5. 42 to 43
6. 44 to 45
7. 46 to 47
8. 48 to 49
9. 50 to 51
10. 52 to 53
11. 54 to 55
12. 56 to 57
13. 58 to 59
14. 60 to 61
15. 62 to 63
16. 64 to 65
17. 66 and above

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TABLE 5. (Cont’d) STATISTICAL DATA CODES − PROFILES

Prof. No. Description Count Conditions
415 Engine Speed 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 ENGINE SPEED RANGE (RPM)
1. 750 and below
2. 751 to 850
3. 851 to 950
4. 951 to 1050
5. 1051 to 1150
6. 1151 to 1250
7. 1251 to 1350
8. 1351 to 1450
9. 1451 to 1550
10. 1551 to 1650
11. 1651 to 1750
12. 1751 to 1850
13. 1851 to 1950
14. 1951 to 2050
15. 2051 to 2150
16. 2151 to 2250
17. 2251 and above
416 Engine Cranking This is a histogram of the time duration of active engine cranking commands
Command Active 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 ENGINE CRANKING COMMAND ACTIVE (SEC)
1. 1 and below
2. 2 to 4
3. 5 to 6
4. 7 to 8
5. 9 to 10
6. 11 to 15
7. 16 to 20
8. 21 to 25
9. 26 to 30
10. 31 to 40
11. 41 to 50
12. 51 to 60
13. 61 to 70
14. 71 to 80
15. 81 to 90
16. 91 to 100
17. 101 and above

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TABLE 5. (Cont’d) STATISTICAL DATA CODES − PROFILES

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

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TABLE 5. (Cont’d) STATISTICAL DATA CODES − PROFILES

Prof. No. Description Count Conditions
419 RSC Percentage 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. 6 or less
2. 6.1 to 12
3. 12.1 to 18
4. 18.1 to 24
5. 24.1 to 30
6. 30.1 to 36
7. 36.1 to 42
8. 42.1 to 48
9. 48.1 to 54
10. 54.1 to 60
11. 60.1 to 66
12. 66.1 to 72
13. 72.1 to 78
14. 78.1 to 84
15. 84.1 to 90
16. 90.1 to 96
17. 96.1 or greater
420 Pot Reference 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. 5 or less
2. >5 to ≤8
3. >8 to ≤8.5
4. >8.5 to ≤9
5. >9 to ≤9.5
6. >9.5 to ≤10
7. >10 to ≤10.5
8. >10.5 to ≤11
9. >11 to ≤11.5
10. >11.5 to ≤12
11. >12 to ≤12.5
12. >12.5 to ≤13
13. >13 to ≤13.5
14. >13.5 to ≤14
15. >14 to ≤14.5
16. >14.5 to ≤15
17. >15.1 or greater

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TABLE 5. (Cont’d) STATISTICAL DATA CODES − PROFILES

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

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TABLE 5. (Cont’d) STATISTICAL DATA CODES − PROFILES

Prof. No. Description Count Conditions
422 Speed Loaded 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. 2.5 or less
2. >2.5 to 5
3. >5 to ≤7.5
4. >7.5 to ≤10
5. >10 to ≤12.5
6. >12.5 to ≤15
7. >15 to ≤17.5
8. >17.5 to ≤20
9. >20 to ≤22.5
10. >22.5 to ≤25
11. >25 to ≤27.5
12. >27.5 to ≤30
13. >30 to ≤32.5
14. >32.5 to ≤35
15. >35 to ≤37.5
16. >37.5 to ≤40
17. 40 or greater
423 Hyd Brake Deg 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 buck-
et. The buckets are defined as follows: (Truck_type = 320 Ton AC only.)
NUMBER TEMPERATURE RANGE
1. <20
2. >20 to ≤40
3. >40 to ≤50
4. >50 to ≤60
5. >60 to ≤70
6. >70 to ≤80
7. >80 to ≤90
8. >90 to ≤95
9. >95 to ≤100
10. >100 to ≤105
11. >105 to ≤110
12. >110 to ≤115
13. >115 to ≤120
14. >120 to ≤125
15. >125 to ≤130
16. >130 to ≤140
17. >140

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TABLE 5. (Cont’d) STATISTICAL DATA CODES − PROFILES

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

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TABLE 5. (Cont’d) STATISTICAL DATA CODES − PROFILES

Prof. No. Description Count Conditions
426 Motor 1 Hi RPM This is a histogram of the Motor 1 RPM. The sample time is every 1.0 sec-
onds. 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 buck-
ets are defined as follows:
NUMBER RPM
1. ≤3300
2. >3300 to 3400
3. >3400 to ≤3500
4. >3500 to ≤3600
5. >3600 to ≤3700
6. >3700 to ≤3800
7. >3800 to ≤3900
8. >3900 to ≤4000
9. >4000 to ≤4100
10. >4100 to ≤4200
11. >4200 to ≤4300
12. >4300 to ≤4400
13. >4400 to ≤4500
14. >4500 to ≤4600
15. >4600 to ≤4700
16. >4700 to ≤4800
17. >4800
427 Motor 2 Hi RPM This is a histogram of the Motor 2 RPM. The sample time is every 1.0 sec-
onds. 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 buck-
ets are defined as follows:
NUMBER RPM
1. ≤3300
2. >3300 to 3400
3. >3400 to ≤3500
4. >3500 to ≤3600
5. >3600 to ≤3700
6. >3700 to ≤3800
7. >3800 to ≤3900
8. >3900 to ≤4000
9. >4000 to ≤4100
10. >4100 to ≤4200
11. >4200 to ≤4300
12. >4300 to ≤4400
13. >4400 to ≤4500
14. >4500 to ≤4600
15. >4600 to ≤4700
16. >4700 to ≤4800
17. >4800
428 − spare
440

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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 (Figure 61). The
message lines provide propulsion system operating information, test status information, and function key label
information, depending upon the DID panel’s mode of display. The function keys assume different functionality
depending upon the DID panel’s mode of display.

8.1. DISPLAY SELECTION

The DID panel provides additional functionality with Version 20 software from that available with Version 19. There
is an additional layer of display selections with Version 20 software. Refer to Figure 62 for an overview of the hierarchy
of the displays available. Figures and paragraphs within this section are marked for the applicable software version.

Pressing Menu (F4) from the Normal or Faults display accesses the first layer of selections. This is the only layer
of selections with Version 19 software and a test/information selection is made by pressing the desired function key
(F1, F2, F3, F4). With Version 20 software, pressing Menu (F4) accesses an additional layer of menu selections for
Test, Info, and Inv Cut Out. Pressing the desired function key (F1, F2, F3) then accesses the menu for that function
key. Test/Info/Inv Cut Out selection is then made by pressing the desired function key from this menu layer. Display
selection function keys (soft keys) are shown in Figure 61.

MENU/MESSAGE LINE

MENU/MESSAGE LINE SOFT KEYS − SOFT

KEY FUNCTIONS
F1 F2 F3 F4 F5 WILL BE DESCRIBED
IN THE SECTION OF
THIS PUBLICATION
SOFT KEYS WHERE THEY ARE
A B C D E USED.
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM

E−44469C

Figure 61. DID Panel Identification.

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Section 8.4
V19 MENU
F4

LOAD SW CAP OVER

BOX VER TEST SPEED
F1 F2 F3 F4
Sec. 8.6.1 Sec. 8.6.2 Sec. 8.6.3 Sec. 8.6.4

MENU
F4

TEST INFO INV

MENU MENU CUTOUT
F1 F2 F3

INV INV
LOAD CAP SPEEDO #1 #2
BOX TEST TEST F1 F2
F1 F2
Sec. 8.6.8 Sec. 8.6.8
F4
Sec. Sec. 8.6.3 Sec. 8.6.5
8.6.1

GY19 GY19
Automatic Manual
Adjust Adjust

SW OVER VIEW VIEW

VER SPEED PARAMS STATS
F1 F2 F3 F4
Sec. 8.6.2 Sec. 8.6.4 Sec. 8.6.6 Sec. 8.6.7

E−45386C

Figure 62. DID Panel Hierarchy.

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0/ 0/GE propulsion control system OK

Propulsion Mode = REST MENU ESPANOL

F1 F2 F3 F4 F5

A B C D E
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM
E−47804

Figure 63. DID Panel Example − Normal Display (No Faults).

8.2. MODES DISPLAY (VERSION 19/20)

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 (Figure 63).

The display will indicate one of the following modes of operation:

1. REST − The REST rocker switch is in the ON position and both the AC OHV propulsion system and the truck
are in the appropriate condition for the REST mode to be active.

2. TEST − The AC OHV propulsion system is in a self−test mode of operation.

3. READY − The AC OHV propulsion system is ready for powering.

4. PROPEL − The AC OHV propulsion system is powered up and the Direction Selector switch is either in
FORWARD or REVERSE.

5. RETARD − The AC OHV propulsion system is powered up and retard effort is commanded either from the
retard pedal or retard speed control.

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8.3. FAULTS DISPLAY (VERSION 19/20)

Whenever there are active faults, this is the active DID panel message display (Figure 64). The DID panel faults
display will show the most recent active fault as well as the number of active faults that are currently stored.

The function keys in the DID panel’s Faults Display mode screen provide the user with the following capabilities:
(Figure 65)

1. Function key F1 (Up) moves the display UP through the active fault list, thereby displaying detailed information
regarding the fault of interest.

2. Function key F2 (Down) moves the display DOWN through the active fault list, thereby displaying detailed
information regarding the fault of interest.

48/ 1−Shorted DC Link at Startup

LIST Num Events = 3 MENU ESPANOL

F1 F2 F3 F4 F5

A B C D E
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM
E−47805

Figure 64. DID Panel Message Example − Fault Display.

92/ 1−Inverter 2 Cutout

Up Down Return Reset

F1 F2 F3 F4 F5

A B C D E
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM
E−47806

Figure 65. DID Panel Message Example − Faults Display Function Keys.

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

48/ 1 Shorted DC Link at Startup

Reset1 RESET* cancel

F1 F2 F3 F4 F5

A B C D E
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM

E−47807

Figure 66. DID Panel Message Example − Fault Reset Function Keys.

3. Function key F3 (Return) returns the user to the previous display.

4. Function key F4 (Reset) enables the user to subsequently perform fault reset functions as follows: (Figure 66)

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.

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.

8.4. DISPLAY DESCRIPTIONS (VERSION 19/20)

The following sections describe the displays that are available.

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8.4.1. Self Load Testing (Version 19/20)

Press the applicable function keys (V19, F4 −> F1 or V20, F4 −> F1 −> F1) to access the Load Box screen.
Commands now available to the user are as follows:

1. Pressing function key F2 (Enter) requests Load Box mode of operation (Figure 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 (Figure 68).

2. Pressing function key F5 (Return) stops the Load Box Test and returns the user to the DID Test Display
mode or the Test Menu mode (V20, Figure 69).

Ready to Enter Loadbox Mode

Enter Return

F1 F2 F3 F4 F5

A B C D E
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM
E−47809

Figure 67. DID Panel Message Example − Load Box Test Function Keys.

TURN NHP = 2606 ENGLOAD= 5.0 LDBX

MAN ON HPADJ = 200 GFAULT = −0 EXIT

F1 F2 F3 F4 F5

A B C D E
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM
E−47810

Figure 68. DID Panel Message Example − Load Box Test Data.

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

Load Cap CD Speedo

Box Test Test Meter Return

F1 F2 F3 F4 F5

A B C D E
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM

E−48420

Figure 69. DID Panel Message Example − Test Menu.

8.4.2. Software Version Display (Version 19/20)

Press the applicable function keys (V19, F4 −> F2 or V20, F4 −> F2 −> F1) to access the PSC Software Version
display. This displays the PSC Software Version that is loaded in the AC OHV propulsion system. Subsequent
pressing of the F2 (Next) function key will display the following information in the order listed:

1. PSC software version (Figure 70)

2. Inverter #1 software version

3. Inverter #2 software version

PSC Software Ver = 19.03a

Next Return

F1 F2 F3 F4 F5

A B C D E
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM
E−47811

Figure 70. DID Panel Message Example − PSC Software Version Data.

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 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

4. TCI software version

5. TCI base configuration version

Pressing function key F5 (Return) at any time while in the Software Version display will return the user to the DID
panel Test Display mode or the Info Menu mode (V20, Figure 71).

SU Over View View

Vers Speed Params Stats Return

F1 F2 F3 F4 F5

A B C D E
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM
E−47812

Figure 71. DID Panel Message Example − V20 Info Menu.

8.4.3. Link Capacitance Testing (Version 19/20)

Press the applicable function keys (V19, F4 −> F3 or V20, F4 −> F1 −> F2) to invoke the Link Capacitance Test.
The results of the Link Capacitance Test are then automatically displayed (Figure 72). Commands now available to
the user are as follows:

1. Pressing function key F2 (Start) will start the Link Capacitance Test again.

2. Pressing function key F5 (Return) will return the user to the DID panel Test Display mode or the Test Menu
mode (V20, Figure 69).

3. Pressing function key F5 (Return) again will return the user to the DID panel’s Normal mode display (V19,
Figure 63) or the Menus Display mode.

8.4.4. Overspeed Setting (Version 19/20)

Press the applicable function keys (V19, F4 −> F4 or V20, F4 −> F2 −> F2) to access the Overspeed Settings
display. This displays the Overspeed Settings that are loaded in the AC OHV propulsion system (Figure 73).

1. Pressing function key F5 (Return) will return the user to the DID panel Test Display mode or the Info Menu
mode (V20, Figure 71).

2. Pressing function key F5 (Return) again will return the user to the DID panel’s Normal mode display (V19,
Figure 63) or the Menus Display mode.

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

Link Capacitance (uf) = 21600

Start Return

F1 F2 F3 F4 F5

A B C D E
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM
E−47813

Figure 72. DID Panel Message Example − Link Capacitance Test Data.

Max Truck Speed Loaded = 40.0

Max Truck Speed Unloaded = 40.0 Return

F1 F2 F3 F4 F5

A B C D E
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM
E−47814

Figure 73. DID Panel Message Example − Overspeed Setting Data.

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8.4.5. Gate Driver Test (Version 20)

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.

Press the applicable function keys (V20, F4 −> F1 −> F3) to display the Gate Driver Test (Figure 74). The Gate
Driver Test turns the gate drivers ON so that the fiber optics can be manually checked. Commands now available to
the user are as follows:

WARNING: When viewed under some conditions, the optical port may expose the eye beyond the
maximum permissible exposure recommended in ANSI z136.2, 1993.

1. Press function key F2 (Proceed) to start the Gate Driver Test (begin turning on the gate drivers).

2. A Warning displays and F4 (Proceed) must be pressed to acknowledge the Warning and begin turning on the
gate drivers (Figure 75).

WARNING: When the Gate Drivers are ON, 100 V AC is applied at the module. Follow all standard safety
precautions for checks at this voltage level.

3. The gate drivers will now turn ON (Figure 76). Press function key F5 (Exit) to turn the gate drivers OFF and
return to the DID panel’s Test Menu mode (Figure 69).

Turn on Gate Drivers 1 and 2

Proceed Return

F1 F2 F3 F4 F5

A B C D E
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM
E−47878

Figure 74. DID Panel Message Example − Gate Driver Test Selection.

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WARNING: Enabling this test applies

100V at the modules: Proceed Cancel

F1 F2 F3 F4 F5

A B C D E
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM

E−47879

Figure 75. DID Panel Message Example − Gate Driver Test Warning.

Gate Drive Power Supplies ON

Exit

F1 F2 F3 F4 F5

A B C D E
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM
E−47880

Figure 76. DID Panel Message Example − Gate Driver Test In Progress.

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 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

8.4.6. Speedometer Test (Version 20)

Press the applicable function keys (V20, F4 −> F1 −> F4) to display the Speedometer Test (Figure 77). The
Speedometer Test generates a specific mph reading so that the speedometer can be tested or calibrated (default is
20 mph). Commands now available to the user are as follows:

1. Press function key F2 (Begin) to start the Speedometer Test.

2. Press function keys F1, F2, F3, F4 as required to calibrate the speedometer (Figure 78).

3. Press function key F5 (Exit) to exit the Speedometer Test and return to the DID panel’s Test Menu mode
(Figure 69).

Ready to Test Speedometer

Begin Exit

F1 F2 F3 F4 F5

A B C D E
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM
E−47815

Figure 77. DID Panel Message Example − Speedometer Test Selection.

Speedometer Test Value = = 20

Dec 5 Dec Inc Inc 5 Exit

F1 F2 F3 F4 F5

A B C D E
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM
E−47816

Figure 78. DID Panel Message Example − Speedometer Test in Progress.

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8.4.7. View Parameters (Version 20)

Press the applicable function keys (V20, F4 −> F2 −> F3) to display View Parameters (Figure 79). Enter the
known parameter number (or enter any number) using the 0 − 9 numbered keys, press F3 (Enter), and the parameter
value will be displayed in real time (Figure 80). (Press F5, Cancel, to cancel the entered number.) Commands now
available to the user are as follows:

1. Press function key F1 (New) to return to the View Parameters display (Figure 79) and enter a new parameter
number directly.

2. Press function key F2 (Prev) or F3 (Next) to proceed sequentially through the parameter list.

3. Press function key F5 (Exit) to exit View Parameters and return to the DID panel’s Info Menu mode (Figure
71).

Enter Parameter # ’ = 82
Enter Cancel

F1 F2 F3 F4 F5

A B C D E
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM
E−47817

Figure 79. DID Panel Message Example − View Parameters Selection.

23: crankbatt_ail3 = 23.906

New Prev Next Exit

F1 F2 F3 F4 F5

A B C D E
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM
E−47818

Figure 80. DID Panel Message Example − View Parameters Display.

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8.4.8. View Stats (Version 20)

Press the applicable function keys (V20, F4 −> F2 −> F4) to display View Stats (Figure 81). This feature displays
the Mine Level Counters one at a time. Enter the desired number using the 0 − 9 numbered keys, press F3 (Enter),
and the stat value will be displayed in real time (Figure 82). (Press F5, Cancel, to cancel the entered number.)
Commands now available to the user are as follows:

1. Press function key F1 (New) to return to the View Stats display (Figure 81) and enter a new stat number
directly.

2. Press function key F2 (Prev) or F3 (Next) to proceed sequentially through the statistic list.

Enter Counter # (301−388) : = 302

Enter Cancel

F1 F2 F3 F4 F5

A B C D E
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM
E−47819

Figure 81. DID Panel Message Example − View Stats Selection.

302:Control Pwr On= 902 Hours−LIFE

New Prev Next Time Exit

F1 F2 F3 F4 F5

A B C D E
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM
E−47820

Figure 82. DID Panel Message Example − View Stats Display.

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

3. Press function key F4 (Time) to proceed to the Time Interval display (Figure 83) and select the desired interval
using the 1 − 7 numbered keys. When the desired key is pressed, that time interval will be selected and the
View Stats display will appear again automatically (function keys F1 − F5 are not active on this display).

4. Press function key F5 (Exit) to exit View Stats and return to the DID panel’s Info Menu mode (Figure 71).

8.4.9. Inverter Cutout (Version 20)

Press the applicable function keys (V20, F4 −> F3) to display Inverter Cutout (Figure 84). This displays the
inverter selections (Inv #1, Inv #2). (Press F5, Return, to return to the DID panel’s Menus mode. Commands now
available to the user are as follows:

1=Today 2=Yes1 3−This Month 4=Lst Month

5=This Qtr 6=Last Qtr 7=Life

F1 F2 F3 F4 F5

A B C D E
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM
E−47821

Figure 83. DID Panel Message Example − View Stats Interval Change.

Inv Inv
#1 #2 Return

F1 F2 F3 F4 F5

A B C D E
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM
E−47822

Figure 84. DID Panel Message Example − Inverter Cutout Selection.

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Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

Inverter # 1 = CUT−IN
Toggle Return

F1 F2 F3 F4 F5

A B C D E
1 2 3 4 5
F S + − *
6 7 8 9 0

SHIFT CLEAR SPACE BRIGHT ENTER

DELETE DIM
E−47823

Figure 85. DID Panel Message Example − Inverter Cutout Status Display.

1. Press function key F1 (Inv #1) or F2 (Inv #2) to select the inverter and proceed to the Inverter Status display
(Figure 85).

2. Press function key F4 (Toggle) to change the status of the selected inverter.

3. Press function key F5 (Return) to return to the Inverter Cutout display (Figure 84).

4. Repeat steps 1 − 3 for the other inverter if desired, then press function key F5 (Return) to exit Inverter Cutout
and return to the DID panel’s Menus mode.

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 mode to remove power from the
DC link during the troubleshooting of propulsion system circuitry and components.

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9.1. EVENT NUMBERS

The event numbers that appear on the DID panel display in the operator’s cab (and the wPTUt Toolbox) consist of
three (3) digits. The source of the event detection information is as follows:

Event Number Range Event Source

000 through 099 PSC − Propulsion System Controller
100 through 199 Inverter #1
200 through 299 Inverter #2
600 through 699 TCI − Truck Control Interface

9.2. 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 Description
NO PROPEL / LOADBOX 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 POWER No Retard (red) light is illuminated in the operator cab. No propulsion effort
or retard effort is allowed. The DC link is deenergized.
SPEED LIMIT / SYSWARN Propel System Caution (yellow) light is illuminated in the operator cab.
Propel and Retard effort is allowed. The DC link is energized. A speed limit
restriction is imposed on the truck.
INVERTER 1 DISABLE Inverter/wheel motor #1 is disabled. Limited propulsion and retard effort is
available. A speed limit restriction is imposed on the truck.
INVERTER 2 DISABLE Inverter/wheel motor #2 is disabled. Limited propulsion and retard effort is
available. A speed limit restriction is imposed on the truck.
ENGINE SPEED / RP The engine speed is raised and RP1 is closed in response to a potential
Retard circuit problem.
SYSEVENT No restrictions are imposed; the event is logged for information purposes
only.

TABLE 6 or TABLE 7 lists all the events for the GE OHV AC propulsion system and their associated restriction
levels.

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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 6 or TABLE 7 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. 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.
2. From the window browser, select PTU Screens −> TCI −> Special_Tasks −> Event_Menu (Figure 86).
3. The Event_Menu list of screens is now displayed. Double−click on the desired screen to display it.

E−45241A

Figure 86. TCI Event_Menu Screens Access Sequence.

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

9.4.1. View TCI Event Summary Screen

Perform the following to view the TCI Event Summary screen.

1. From the Event_Menu, double−click on TCI Event Summary to select that screen (Figure 86).
2. The TCI Event Summary screen is now displayed (Figure 87).
This screen contains the following information for each recorded event:
a. The name and number for each event

b. The sub−ID for each event. (Events with only one sub−ID will have 01 as their sub−ID.)

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.

E−44368B

Figure 87. TCI Event Summary Screen.

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9.4.2. View TCI Trigger Data Screen

Perform the following to view the TCI Trigger Data screen.

1. From the Event_Menu, double−click on TCI Trigger Data to select that screen (Figure 86).
2. The TCI Trigger Data screen is now displayed (Figure 88).
The TCI Trigger Data screen is a real time screen, similar to Figure 45. 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.

E−45242A

Figure 88. TCI Trigger Data Screen.

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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. From the Event_Menu, double−click on TCI Data Packs to select that screen (Figure 86).
2. The TCI Data Packs screen is now displayed (Figure 89).
This screen contains the following information for each data pack:
a. The data pack number

b. The associated event number and sub−ID 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.

E−44369B

Figure 89. TCI Data Packs Screen.

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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. From the Event_Menu, double−click on Reset TCI Events to select that screen (Figure 86).
2. The Reset TCI Events screen is now displayed (Figure 90).

3. 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.

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. From the Event_Menu, double−click on Erase TCI Events to select that screen (Figure 86).
2. The Erase TCI Events screen is now displayed (Figure 91).

3. 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.

E−45244

Figure 90. Reset TCI Events Screen.

E−45245

Figure 91. Erase TCI Events Screen.

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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 PTU 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.
2. From the window browser, select PTU Screens −> TCI or PSC −> Special_Tasks −> Events & Inv Params
(Figure 86).
3. The Events & Inv Params screen is now displayed (Figure 92).
4. 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).

5. Close the list by clicking on the X in the upper right corner of the screen.

6. Close the Events & Inv Params display screen by clicking on the X in the upper right corner of the screen.

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 serial port.

E−44370A

Figure 92. Events & Inv Params Screen.

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TABLE 6. EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG498 GTO INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
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.
000−No Fault None No faults present.
002−High Ground Fault NO POWER Ground fault detected.
For voltage < 1000 V, detection threshold is 166 mA
For voltage >= 1000 V, detection threshold ramps from 166 mA at
1000 V down to approximately 70 mA at approximately 1500 V
003−Failed Diode NO POWER Failed diode in main rectifier detected.
004−GF Cutout Not SYS EVENT Generator Field Cut−Out switch (GFCO) moved to cut−out position
Reset while propulsion system not in REST Mode (link is energized).
005−Drive System NO PROPEL A component of the propulsion system, identified by the following
Overtemp sub−ID, exceeded its operational temperature limit:

:01−Auxiliary Blower Control Phase Control Rectifier (AUXPC)

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

:01−Persistently above a level

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

:01−Signal volts too high

:02−Signal volts too low
012−Retard Pedal Bad SYS EVENT The received signal from the Retard Pedal exceeded a limit, as iden-
tified by the following sub−ID:

:01−Signal volts too high

:02−Signal volts too low

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TABLE 6. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG498 GTO INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
013−Midvolt Test Failure NO POWER Inverter failed its mid−voltage self test.
014−Analog Sensor SPEED LIMIT The received signal from a sensor, identified by the following sub−ID,
Fault exceeded a limit:

:01−Alternator Field Current

:03−Loadbox Current (LDBX)
:04−Alternator 3−Phase Voltage
:05−Alternator Field Volts
:10−PSC Link Voltage
:11−Inverter No. 1 Link Voltage
:12−Inverter No. 2 Link Voltage
:13−A2D Ground
:14−A2D Gain
:15−Fault Current
:16−ATOC
:21−DB Grid Blower No. 1 Current
:22−DB Grid Blower No. 2 Current
015−Restrictive Analog NO POWER The received signal from a sensor, identified by the following sub−ID,
Sensor Fault exceeded a limit:

:02−Link Current
016−PSC CPU Card NO POWER A problem occurred with a PSC CPU card task, as identified by the
following sub−ID:

:01−Task 1 failed to initialize

:02−Task 2 failed to initialize
:03−Task 3 failed to initialize
:04−Task 4 failed to initialize
:05−Task 5 failed to initialize
:06−Task 6 failed to initialize
:07−Maintenance task failed to initialize
:09−FLASH CRC computation did not match expected value
:10−BRAM CRC computation did not match expected value
:11−Tasks took too long to initialize
:12−BBRAM data pack pointers corrupted
017−PSC Digital I/O NO POWER PSC CPU lost communication with the FB104 PSC digital I/O card.
Card Fault
018−PSC Analog I/O NO POWER PSC CPU lost communication with the FB143 PSC analog I/O card,
Card Fault as further identified by the following sub−ID:

:01−PSC Analog I/O card missing

:02−PSC Analog I/O communication timed out
019−Riding Retard Pedal SYS EVENT Brake and Propel Pedal signals simultaneously received and truck
speed greater than 5 mph.
020−High Torque NO PROPEL Low speed torque limit exceeded.
Timeout

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TABLE 6. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG498 GTO INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
021−TCI Comm Fault NO PROPEL PSC lost or received corrupted communication from TCI, as further
identified by the following sub−ID:

:01−Message Missing
:02−Bad Tick
:03−Bad CRC
:04−Overflow
:05−Bad Start
:06−Bad Stop
022−Persistent TCI NO POWER PSC detected persistent lost or corrupted communication from TCI
Comm Fault over a period of time with truck stopped.
023−Tertiary Overcurrent NO POWER Alternator field tertiary current limit exceeded.
024−PSC ConFigureFile NO POWER Incorrect or missing PSC configuration file detected, as further identi-
fied by the following sub−ID:

:01−Configuration file not loaded

:02−Configuration file CRC computation failed
:03−Configuration file has incorrect major release number
:04−Overspeed values in configuration file are incorrectly set.
025−Aux Blower System NO POWER Problem with the auxiliary blower control system detected, as further
identified by the following sub−ID:

:01−Auxiliary blower control speed feedback indicates no or incorrect

blower speed
:02−Frequent auxiliary blower control fault shutdowns
026−Cap Overpressure NO POWER Filter capacitor overpressure failure detected, as further identified by
the following sub−ID:

:01−Inverter No. 1 filter cap overpressure

:02−Inverter No. 2 filter cap overpressure
027−Panel Not NO POWER One of PSC panel connectors not connected properly. Further identi-
Connected at Power fied by the following sub−ID:
Up
:01−CNFB
:02−CNI/CNX (3500 HP, 150 Ton)
:03−Aux blower connector
030−GF Contactor SPEED LIMIT GF contactor command and feedback do not agree.
031−Battery Boost SPEED LIMIT GFR contactor failed to open or close when commanded. Further
Circuit identified by the following sub−ID:

:01−GFR failed to open

:02−GFR failed to close
:03−SCR3 failed
032−RP Contactor SPEED LIMIT & STUCK RP1 contactor command and feedback do not agree. Further identi-
RP fied by the following sub−ID:

:01−RP1
:02−RP2
:03−RP3
033−Retard Circuit SPEED LIMIT & STUCK
RP

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TABLE 6. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG498 GTO INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
035−Engine Speed SPEED LIMIT Engine speed signal exceeded upper or lower limit.
Sensor
036−GY19 Grid Blower NO POWER Grid blower failure detected, further identified by the following sub−
ID:

:01 − Grid blower stalled

:02 − Grid blower open
037−Computer Power SPEED LIMIT Computer Power Supply voltages exceeded upper or lower limit,
Supply further identified by the following sub−ID:

:01−5 VDC positive

:02−15 VDC positive
:03−15 VDC negative
040−Volts 24 Positive SPEED LIMIT +24V Power Supply exceeded upper or lower limit.
041−Volts 24 Negative SPEED LIMIT −24V Power Supply exceeded upper or lower limit.
042−Direction NO PROPEL Forward or Reverse Switch command received while in Selfload
Requested During Mode of operation.
Selfload
043−Propulsion Battery SPEED LIMIT Propulsion system battery voltage below low limit.
Voltage Low
044−Propulsion Battery SYS EVENT Propulsion system battery voltage above high limit.
Voltage High
045−Chopper Open SPEED LIMIT Chopper Module failed during chopper self test, further identified by
Circuit the following sub−ID:

:01−Chopper 1
:02−Chopper 2
046−Retard Short Circuit SPEED LIMIT & EN- Failure during chopper self test. Link voltage decayed too quickly
GINE SPD when AFSE command set low, prior to starting test.
047−Engine Stall NO POWER Engine stall condition detected.
048−Shorted DC Link NO POWER System detected a potential short on the DC link while attempting to
During Startup charge link.
051−Tach Left Rear INV1 DISABLE Problem occurred with tach on left rear wheelmotor, further defined
by the following sub−ID:

:01−Tach signal indicating zero wheel movement when others are

indicating movement
:02−Tach signal indicating wheel movement when others are
indicating zero movement
052−Tach Right Rear INV2 DISABLE Problem occurred with tach on right rear wheelmotor, further defined
by the following sub−ID:

:01−Tach signal indicating zero wheel movement when others are

indicating movement
:02−Tach signal indicating wheel movement when others are
indicating zero movement

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TABLE 6. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG498 GTO INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
053−Tach Left Front SYS EVENT Problem occurred with tach on left front wheelmotor, further defined
by the following sub−ID:

:01−Tach signal indicating zero wheel movement when others are

indicating movement
:02−Tach signal indicating wheel movement when others are
indicating zero movement
054−Tach Right Front SYS EVENT Problem occurred with tach on right front wheelmotor, further defined
by the following sub−ID:

:01−Tach signal indicating zero wheel movement when others are

indicating movement
:02−Tach signal indicating wheel movement when others are
indicating zero movement
055−Front Wheel Tachs SYS EVENT Problem occurred with tachs on front wheel motors.
056−Inverter Software SYS EVENT Incorrect version of Inverter Software is installed. Further identified
Version by the following sub−ID:

:01−Inverter #1
:02−Inverter #2
061−Motor Overspeed SYS EVENT Truck exceeded motor overspeed limit.
063−Engine Load Signal SYS EVENT The Engine Load Signal feedback from the engine controller is out-
Fault side of limit, further defined by the following sub−ID:

:01−Below minimum value

:02−Above maximum value
:03−PWM signal failed low
:04−PWM signal failed high
:05−PWM signal failed incorrect period
065−Analog Input Range SPEED LIMIT (10 MPH) Analog input outside its design range, further identified by the follow-
Check ing sub−ID:

:01−Auxiliary blower control phase controller temperature

:02−Auxiliary blower control inverter temperature
:03−Alternator field static exciter temperature
:04−Alternator temperature
:05−Left rear wheel motor stator temperature
:06−Left rear wheel motor rotor temperature
:07−Right rear wheel motor stator temperature
:08−Right rear wheel motor rotor temperature
:09−Chopper module GTO temperature
:10−Chopper module diode temperature
:11−Left rear wheel motor inverter GTO temperature
:12−Left rear wheel motor inverter diode temperature
:13−Right rear wheel motor inverter GTO temperature
:14−Right rear wheel motor inverter diode temperature
:15−Rectifier diode temperature
070−Link Capacitance SYS EVENT Link capacitance low, but acceptable for operation.
Low Caution
071−Link Capacitance SPEED LIMIT (10 MPH) Link capacitance low, but acceptable for operation.
Low Warning

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TABLE 6. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG498 GTO INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
072−Ground Circuit SPEED LIMIT (10 MPH) Problem detected with ground fault detection circuit which is typically
associated with failure of the filter capacitor test to discharge the ca-
pacitors within 30 seconds.
074−Inverter1 Comm INV1 DISABLE Communication attempt with Inverter #1 timed out. Inverter 1 not cut-
Failed out. Further identified by the following sub−ID:

:01−No communication Inverter #1

:02−Inverter #1 customer option bit
075−Inverter 2 Comm INV2 DISABLE Communication attempt with Inverter #2 timed out. Inverter 2 not cut-
Failed out. Further identified by the following sub−ID:

:01−No communication Inverter #2

:02−Inverter #2 customer option bit
076−FB173 Card NO POWER A failure in the FB173 card was detected, further identified by the
following sub−ID:

:01−Speed FPGA did not download correctly

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

085−Auxiliary Cooling SYS EVENT Problem detected with auxiliary blower control system, further identi-
Fault fied by the following sub−ID:

:02−Auxiliary blower motor speed signal out of range

:03−Excessive difference between auxiliary blower motor speed
feedback and auxiliary blower motor speed command
:04−Abnormal shutdown of auxiliary blower control system
087−HP Low SYS EVENT Propulsion system adjusted HP load on engine has been reduced to
its minimum value for an excessive period of time.

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TABLE 6. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG498 GTO INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
088−HP Limit SYS EVENT Excessive propulsion system demand on available engine HP, fur-
ther identified by the following sub−ID:

:01−Propulsion system HP demand in propel mode exceeds

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

:02−Allowable difference between engine command and actual

engine speed exceeded
091−Inverter 1 cutout SYS EVENT Inverter 1 is cutout.
092−Inverter 2 cutout SYS EVENT Inverter 2 is cutout.
094−Illegal Limp Mode SYS EVENT Limp Mode requested (i.e. inverter 1 or 2 cutout switch actuated)
when truck is moving.
095−Bad BRAM Battery SYS EVENT BRAM battery voltage below acceptable limit.
096−Unexpected System SYS EVENT PSC CPU reset detected without reset request.
Reset
098−Data Store SYS EVENT PSC data store commanded via PTU.
NOTE: Faults 100 − 199 as shown in 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.
100−Inverter 1/2 CPU INV 1/2 OFF SPEED Restrictive Inverter 1/2 CPU card problem detected.
Card Restrictive LIMIT (10 MPH)
101−Inverter 1/2 CPU INV 1/2 OFF SPEED Non−Restrictive Inverter 1/2 CPU card problem detected.
Card LIMIT (10 MPH)
Non−Restrictive
102−Inverter 1/2 I/O INV 1/2 OFF SPEED Restrictive Inverter 1/2 I/O card problem detected.
Card Restrictive LIMIT (10 MPH)
103−Inverter 1/2 CPU SYS EVENT Non−Restrictive Inverter 1/2 I/O card problem detected.
Card
Non−Restrictive
104−Inverter 1/2 Fiber INV 1/2 OFF SPEED Inverter 1/2 fiber optic card problem detected.
Optic Card LIMIT (10 MPH)
105−Inverter 1/2 Power INV 1/2 OFF SPEED Inverter 1/2 power supply card problem detected.
Supply Card LIMIT (10 MPH)
106−Inverter 1/2 DC INV 1/2 OFF SPEED DC power wiring problem detected, further defined by the following
Power Wiring LIMIT (10 MPH) sub−ID:

:01−DC power connection open

:02−Link and phase voltage mismatch
107−Inverter 1/2 Gate SYS EVENT Inverter 1/2 gate drive power supply problem detected.
Drive Power Supply
109−Inverter 1/2 Link INV 1/2 OFF SPEED Inverter 1/2 link voltage sensor problem detected.
Voltage Sensor LIMIT (10 MPH)

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TABLE 6. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG498 GTO INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
111−Inverter 1/2 Input INV 1/2 OFF SPEED Inverter 1/2 input filter voltage sensor problem detected.
Filter Voltage Sensor LIMIT (10 MPH)
113−General Inverter 1/2 INV 1/2 OFF SPEED Inverter 1/2 phase current or voltage unbalance or exceeded limit
Restrictive LIMIT (10 MPH) detected.
114−General Inverter 1/2 SYS EVENT Inverter 1/2 electrical noise detected on signal channels or operation-
Non−Restrictive al voltage limits exceeded.
115−Inverter 1/2/System INV 1/2 OFF SPEED Inverter#1/System Controller interface problem detected such as
Controller Interface LIMIT (10 MPH) inconsistent commands, loss of communication, or sensor signals
beyond limits.
116−Inverter 1/2 Phase A INV 1/2 OFF SPEED Inverter#1 Phase A problem detected such as GTO failure to follow
LIMIT (10 MPH) command or Phase A overcurrent.
117−Inverter 1/2 Phase A INV 1/2 OFF SPEED Restrictive Inverter#1 Phase A Positive (+) problem detected such as
Positive (+) LIMIT (10 MPH) module failure to follow command.
Restrictive
118−Inverter 1/2 Phase A SYS EVENT Non−Restrictive Inverter#1 Phase A Positive (+) problem detected.
Positive (+)
Non−Restrictive
119−Inverter 1/2 Phase A INV 1/2 OFF SPEED Restrictive Inverter#1 Phase A Negative (−) problem detected such
Negative (−) LIMIT (10 MPH) as module failure to follow command.
Restrictive
120−Inverter 1/2 Phase SYS EVENT Non−Restrictive Inverter#1 Phase A Negative (−) problem detected.
A Negative (−)
Non−Restrictive
121−Inverter 1/2 Phase INV 1/2 OFF SPEED Inverter#1 Phase A current sensor or Phase A current problem de-
A Current LIMIT (10 MPH) tected.
123−Inverter 1/2 Phase INV 1/2 OFF SPEED Inverter#1 Phase A voltage sensor or Phase A voltage problem de-
A Voltage LIMIT (10 MPH) tected.
125−Inverter 1/2 Phase INV 1/2 OFF SPEED Inverter#1 Phase B problem detected such as GTO failure to follow
B LIMIT (10 MPH) command or Phase B overcurrent.
126−Inverter 1/2 Phase INV 1/2 OFF SPEED Restrictive Inverter#1 Phase B Positive (+) problem detected such as
B Positive (+) LIMIT (10 MPH) module failure to follow command.
Restrictive
127−Inverter 1/2 Phase SYS EVENT Non−Restrictive Inverter#1 Phase B Positive (+) problem detected.
B Positive (+)
Non−Restrictive
128−Inverter 1/2 Phase INV 1/2 OFF SPEED Restrictive Inverter#1 Phase B Negative (−) problem detected such
B Negative (−) LIMIT (10 MPH) as module failure to follow command.
Restrictive
129−Inverter 1/2 Phase SYS EVENT Non−Restrictive Inverter#1 Phase B Negative (−) problem detected.
B Negative (−)
Non−Restrictive
130−Inverter 1/2 Phase INV 1/2 OFF SPEED Inverter#1 Phase B current sensor or Phase B current problem de-
B Current LIMIT (10 MPH) tected.
132−Inverter 1/2 Phase INV 1/2 OFF SPEED Inverter#1 Phase B voltage sensor or Phase B voltage problem de-
B Voltage LIMIT (10 MPH) tected.
134−Inverter 1/2 Phase INV 1/2 OFF SPEED Inverter#1 Phase C problem detected such as GTO failure to follow
C LIMIT (10 MPH) command or Phase C overcurrent.

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TABLE 6. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG498 GTO INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
135−Inverter 1/2 Phase INV 1/2 OFF SPEED Restrictive Inverter#1 Phase C Positive (+) problem detected such as
C Positive (+) LIMIT (10 MPH) module failure to follow command.
Restrictive
136−Inverter 1/2 Phase SYS EVENT Non−Restrictive Inverter#1 Phase C Positive (+) problem detected.
C Positive (+)
Non−Restrictive
137−Inverter 1/2 Phase INV 1/2 OFF SPEED Restrictive Inverter#1 Phase C Negative (−) problem detected such
C Negative (−) LIMIT (10 MPH) as module failure to follow command.
Restrictive
138−Inverter 1/2 Phase SYS EVENT Non−Restrictive Inverter#1 Phase C Negative (−) problem detected.
C Negative (−)
Non−Restrictive
141−Inverter 1/2 Phase INV 1/2 OFF SPEED Inverter#1 Phase C voltage sensor or Phase C voltage problem de-
C Voltage LIMIT (10 MPH) tected.
143−Inverter 1/2 Tach 1 INV 1/2 OFF SPEED Restrictive Inverter#1 Tach 1 signal problem detected.
Restrictive LIMIT (10 MPH)
144−Inverter 1/2 Tach 1 SYS EVENT Non−Restrictive Inverter#1 Tach 1 signal problem detected.
Non−Restrictive
145−Inverter 1/2 Tach 2 SYS EVENT Restrictive Inverter#1 Tach 2 signal problem detected.
Restrictive
146−Inverter 1/2 Tach 2 SYS EVENT Non−Restrictive Inverter#1 Tach 2 signal problem detected.
Non−Restrictive
148−Inverter 1/2 INV 1/2 OFF SPEED Inverter#1 Chopper 1 operational problem detected.
Chopper 1 LIMIT (10 MPH)
150−Inverter 1/2 INV 1/2 OFF SPEED Inverter#1 Chopper 2 operational problem detected.
Chopper 2 LIMIT (10 MPH)
151−Inverter 1/2 Tach INV 1/2 OFF SPEED Excessive difference between Inverter 1/2 Tachs 1 and 2.
Differential LIMIT (10 MPH)
153−Inverter 1/2 Motor INV 1/2 OFF SPEED Inverter 1/2 detected a motor connection problem further defined by
Restrictive LIMIT (10 MPH) the following sub−ID:

:01−Motor connection open

:02−Motor connection short
154−Inverter 1/2 Motor SYS EVENT Inverter 1/2 detected a motor temperature exceeding its limit further
Non−Restrictive defined by the following sub−ID:

:01−Motor rotor temperature high

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

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TABLE 6. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG498 GTO INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
601−TCI CPU Card NO PROPEL A problem was detected with the TCI CPU card, further identified by
FB144 the following sub−ID:

:01−10 msec task failed to initialize

:02−20 msec task failed to initialize
:03−50 msec task failed to initialize
:04−100 msec task failed to initialize
:05−200 msec task failed to initialize
:06−50 msec fault manager task failed to initialize
:07−Flash CRC computation did not match expected value
:09−Maintenance task failed to initialize
:10−Upon power−up, excessive bus time outs occurred
:11−Upon power−up, the status of key memory data in BBRAM was
found to be invalid
:12−CRC on protected areas of BBRAM did not match expected
value
602−FB104 TCI Digital NO PROPEL A problem was detected with the TCI digital I/O card.
I/O Card
603−FB160 TCI Analog NO PROPEL A problem was detected with the TCI analog I/O card.
I/O Card
604−TCI to PSC RS422 SPEED LIMIT (10 MPH) Serial link communication with PSC was lost for a persistent time
Comm period, further identified by the following sub−ID:

:01−Missing message
:02−Bad tick
:03−Bad CRC
:04−FIFO overflow
:05−Bad start bit
:06−Bad stop bit
605−Aux Comm Fault None Serial link communication with the Auxiliary Blower Control System
was lost for a persistent time period.
607−Positive 5 volts SPEED LIMIT (10 MPH) +5V Power Supply exceeded limits for a persistent period of time.
608−Positive 15 Volts SPEED LIMIT (10 MPH) +15V Power Supply exceeded limits.
609−Negative 15 Volts SPEED LIMIT (10 MPH) −15V Power Supply exceeded limits.
610−Pot Reference SPEED LIMIT (10 MPH) Pot Reference exceeded limits.
613−Analog Input SPEED LIMIT (10 MPH) An analog signal input on the analog I/O card exceeded its limits for
a persistent period of time, as defined by the following sub−ID:

:01−Ground (A2D)
:02−Gain Check (A2D)
614−Battery Separate SYS EVENT The battery separate contactor failed to operate in an expected man-
Contactor ner as further defined by the following sub−ID:

:01−Battery separate failure

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

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TABLE 6. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG498 GTO INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
617−Engine Start SYS EVENT The engine start request was denied for the following reason defined
Request Denied by the sub−ID:

:01−Engine warning signal received during cranking

:02−Engine Kill signal received during cranking
619−Engine Warning NO PROPEL The engine warning signal was received when the engine speed is
above the run threshold.
620−Engine Kill while NO PROPEL The engine kill signal was received while the truck was moving.
Moving
622−Park Brake NO PROPEL Unexpected park brake operation defined by the following sub−ID:

:01−Park brake command and feedback do not agree

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

:01−Tank
:02− Left Front Outlet
:03− Right Front Outlet
:04− Left Rear Outlet
:05− Right Rear Outlet
624−Body Up and SPEED LIMIT (10 MPH) Simultaneous receipt of both full payload and body up signals for a
Payload Indication persistent time period.
625−Extended Battery None Excessive time has elapsed between battery separate and subse-
Reconnect Time quent battery reconnection.
628−Connected SYS EVENT Battery volts exceeded limits for a persistent period of time, while
Batteries engine speed is greater than idle and control power is ON; further
defined by the following sub−ID:

:01−Control battery volts below 20 VDC

:02−Control battery volts above 32 VDC
:03−Cranking battery volts below 20 VDC
:04−Cranking battery volts above 32 VDC
629−Barometric SYS EVENT Barometric pressure sensor signal exceeded limits for a persistent
Pressure period of time, further defined by the following sub−ID:

:01−Barometric pressure sensor value too low

:02−Barometric pressure sensor value too high
630−Motor Blower SPEED LIMIT Motor blower pressure signal exceeded limits, indicating a problem
Pressure with the sensor, duct work, or axle box sensor. Further defined by
the following sub−ID:

:01−No cooling air

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

:02−Ambient temperature signal too high

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TABLE 6. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG498 GTO INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
632−TCI Configuration NO PROPEL A problem with the TCI configuration file has been detected, further
File defined by the following sub−ID:

:01−File not loaded

:02−File loaded improperly, resulting in bad CRC
:03−Wrong version of file loaded
633−BBRAM Battery SYS EVENT Battery−backed RAM (BBRAM) battery has failed.
Failure
634−Truck Overloaded NO PROPEL Truck operation restricted when overloaded signal received and TCI
Restrictive configured for restrictive response.
635−Truck Overloaded SYS EVENT Truck operation not restricted when overloaded signal received and
Non−Restrictive TCI configured for non−restrictive response.
636−Aux Inverter Faults SYS EVENT Auxiliary blower control failure has occurred.

:00−No fault condition; initial state on application of control power

:01−Low DC bus voltage detected during powerup
:02−High DC bus voltage detected during operation
:03−Overcurrent condition detected during operation
:05−High DC bus voltage detected during operation
:06−High DC bus voltage detected after phase controller powerup
:07−Low DC bus voltage detected after phase controller powerup
:08−High DC bus voltage detected during operation
:09−Overcurrent condition detected after phase controller powerup
:10−Sustained current overload exists (above rated conditions but
below component safe operating range)
:11−Overcurrent fault due to low DC link voltage
:12−Sustained current overload fault due to low DC link voltage
:13−IGBT protection circuit detected overcurrent
:14−Low or missing AC input voltage detected
638−Engine cranking SYS EVENT The diesel engine was cranking longer than the maximum allowed
timeout cranking time.
639−Engine Start SYS EVENT An Engine Start Request was received while the diesel engine was
Request While running. The engine speed must be greater than 600 rpm and the
Running start request signal must be present for three seconds minimum for
this event to be logged.
640−Accel Pedal Too NO PROPEL Accelerator Pedal input is greater than the maximum value for a spe-
High cified period of time.
641−Accel Pedal Too SYS EVENT Accelerator Pedal input is less than the minimum value for a speci-
Low fied period of time.
696−Unexpected CPU SYS EVENT The TCI CPU was reset while the system was in Self Load, Propel,
Reset Retard, or Ready mode.
698−PTU Data Store SYS EVENT The DATASTORE command was received by the TCI. No corrective
action required.
However, if DATASTORE was not commanded and the event was
logged, check DATASTORE switch and wiring.

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TABLE 7. EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG535 IGBT INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
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.
000−No Fault None No faults present.
002−Ground Fault NO POWER Ground fault detected.
For voltage < 1000 V, detection threshold is 611 mA
For voltage >= 1000 V, detection threshold ramps from 611 mA at
1000 V down to approximately 306 mA at approximately 1500 V
003−Excessive Alterna- NO POWER Alternator Field Transient exceeded threshold, Possibly caused by a
tor Field Transient failed diode in main rectifier.
004−GF Cutout Not in SYS EVENT Generator Field Cut−Out switch (GFCO) moved to cut−out position
REST while propulsion system not in REST Mode (link is energized).
005−Drive System Over- NO PROPEL A component of the propulsion system, identified by the following
temp sub−ID, exceeded its operational temperature limit:

:03−Alternator Field Static Exciter (AFSE)

:04−Alternator
:05−Left Wheelmotor Stator
:06−Left Wheelmotor Rotor
:07−Right Wheelmotor Stator
:08−Right Wheelmotor Rotor
:09−Chopper Module IGBT
:10−Chopper Module Diode
:11−Left Wheelmotor Inverter IGBT
:12−Left Wheelmotor Inverter Diode
:13−Right Wheelmotor Inverter IGBT
:14−Right Wheelmotor Inverter Diode
:15−Rectifier Diode
006−Both INV Comms NO POWER PSC lost communication with both inverters.
Failed
008−DC Link Overvol- NO POWER DC link exceeded a voltage limit, identified by the following sub−ID:
tage
:01−Persistently above a level while not in retard operation
:02−Persistently above a level while in retard operation
:03−Instantaneously above a level regardless of operating mode
009−Alt Field Overcur- NO POWER Alternator field current exceeded a limit, identified by the following
rent sub−ID:

:01−Persistently above a level

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

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TABLE 7. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG535 IGBT INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
012−Retard Pedal Bad SYS EVENT The received signal from the Retard Pedal exceeded a limit, as iden-
tified by the following sub−ID:

:01−Signal volts too high

:02−Signal volts too low
013−Midvolt Test Failure NO POWER System unable to lower link in order to begin the Mid−Volt Startup
Test.
014−Analog Sensor SPEED LIMIT The received signal from a sensor, identified by the following sub−ID,
Fault exceeded a limit:

:01−Alternator Field Current

:04−Alternator 3−Phase Voltage
:05−Alternator Field Volts
:10−PSC Link Voltage
:11−Inverter No. 1 Link Voltage
:12−Inverter No. 2 Link Voltage
:13−A2D Ground
:14−A2D Gain
:15−Fault Current
:16−ATOC
:21−DB Grid Blower No. 1 Current
:22−DB Grid Blower No. 2 Current (If Present)
015−Restrictive Analog NO POWER The received signal from a sensor, identified by the following sub−ID,
Sensor Fault exceeded a limit:

:02−Link Current
016−PSC CPU Card NO POWER A problem occurred with a PSC CPU card software. Reset Faults. If
they reappear this event points to a CPU card issue. If they only
appear immediately after applying power, it points to a low BBRAM
battery.
017−PSC Digital I/O NO POWER PSC CPU lost communication with the FB104 PSC digital I/O card.
Card Fault
018−PSC Analog I/O NO POWER PSC CPU lost communication with the FB173 PSC analog I/O card,
Card Fault as further identified by the following sub−ID:

:01−PSC Analog I/O card missing

:02−PSC Analog I/O communication timed out
019−Riding Retard Pedal SYS EVENT Brake and Propel Pedal signals simultaneously received and truck
speed greater than 5 mph.
020−High Torque Time- NO PROPEL Low speed torque limit exceeded. Excessive time spent at very high
out torque.
021−TCI Comm Fault NO PROPEL PSC lost or received corrupted communication from TCI, as further
identified by the following sub−ID:

022−Persistent TCI NO POWER PSC detected persistent lost or corrupted communication from TCI
Comm Fault over a period of time with truck stopped.
023−Tertiary Overcurrent NO POWER Alternator field tertiary current limit exceeded.

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TABLE 7. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG535 IGBT INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
024−PSC Config File NO POWER Incorrect or missing PSC configuration file detected, as further identi-
fied by the following sub−ID:

:01−Configuration file not loaded

:02−Configuration file CRC computation failed
:03−Configuration file has incorrect major release number
:04−Overspeed values in configuration file are incorrectly set.
025−Propulsion System NO POWER Problem with the auxiliary blower control system detected, as further
Cooling Air. identified by the following sub−ID:

:01−Auxiliary blower control speed feedback indicates no or incorrect

blower speed (If Hydraulic Blower Present)
:
027−Panel Not Con- NO POWER One of PSC panel connectors not connected properly. Further identi-
nected at Power Up fied by the following sub−ID:

:01−CNFB
:02−CNX :
030−GF Contactor SPEED LIMIT GF contactor command and feedback do not agree.
031−Battery Boost Cir- SPEED LIMIT GFR contactor failed to open or close when commanded. Further
cuit identified by the following sub−ID:

:01−GFR failed to open

:02−GFR failed to close
:03−SCR3 failed
032−RP Contactor SPEED LIMIT & STUCK RP1 contactor command and feedback do not agree. Further identi-
RP fied by the following sub−ID:

:01−RP1
:02−RP2 (If Present)
:03−RP3 (If Present)
033−Retard Circuit SPEED LIMIT & STUCK
RP

:01 – Stuck RP contactor or shorted Chopper

:02 – Choppers stuck on.
034−Retard Power Cir- SPEED LIMIT
cuit fault
:01−Detected High Chopper Percent ON – RP2 may not have closed
:02 –Overvoltage Protection Active – RP2 may not have closed
:03 – Link Discharging Error – RP2 May not have closed
:04 – Choppers stuck on
035−Engine Speed Sen- SPEED LIMIT Engine speed signal exceeded upper or lower limit.
sor

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TABLE 7. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG535 IGBT INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
036−GY19 Grid Blower NO POWER Grid blower failure detected, further identified by the following sub−
ID:

:01−Grid blower no. 1 stalled

:02−Grid blower no. 2 stalled (If Present)
:03−Grid blower no. 1 open
:04−Grid blower no. 2 open (If Present)
:05−Excessive difference between grid blower motor currents (2
Blower systems only)
037−Computer Power SPEED LIMIT Computer Power Supply voltages exceeded upper or lower limit,
Supply further identified by the following sub−ID:

:01−5 VDC positive

:02−15 VDC positive
:03−15 VDC negative
040−Volts 24 SPEED LIMIT 24V Power Supply exceeded limit.

:01 − +24 Volts

:02 − −24 Volts
042−Direction Re- NO PROPEL Forward or Reverse Switch command received while in Selfload
quested During Self- Mode of operation.
load
043−Propulsion Battery SPEED LIMIT Propulsion system battery voltage below low limit.
Voltage Low
044−Propulsion Battery SYS EVENT Propulsion system battery voltage above high limit.
Voltage High
045−Chopper Open Cir- SPEED LIMIT Chopper Module failed during chopper self test, further identified by
cuit the following sub−ID:

:01−Chopper 1
:02−Chopper 2
046−Retard Short Circuit SPEED LIMIT & EN- Failure during chopper self test. Link voltage decayed too quickly
GINE SPD when AFSE command set low, prior to starting test.
047−Engine Stall NO POWER Engine stall condition detected.
048−Shorted DC Link NO POWER System detected a potential short on the DC link while attempting to
During Startup charge link.
049 – Communication SYS EVENT A Problem occurred with the Communication Daughter Card
Card (If Present)

:01 Card Reset Unexpectedly

:04 Loss of Comm – Engine CAN Network
:05 Loss of Comm – OEM CAN Network

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TABLE 7. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG535 IGBT INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
051−Tach Left Rear INV1 DISABLE Problem occurred with tach on left rear wheelmotor, further defined
by the following sub−ID:

:01−Tach signal indicating zero wheel movement when others are

indicating movement
:02−Tach signal indicating wheel movement when others are
indicating zero movement
052−Tach Right Rear INV2 DISABLE Problem occurred with tach on right rear wheelmotor, further defined
by the following sub−ID:

:01−Tach signal indicating zero wheel movement when others are

indicating movement
:02−Tach signal indicating wheel movement when others are
indicating zero movement
053−Tach Left Front SYS EVENT Problem occurred with tach on left front wheelmotor, further defined
by the following sub−ID:

:01−Tach signal indicating zero wheel movement when others are

indicating movement
:02−Tach signal indicating wheel movement when others are
indicating zero movement
:03 –Numerous Bad Pulses while moving
054−Tach Right Front SYS EVENT Problem occurred with tach on right front wheelmotor, further defined
by the following sub−ID:

:01−Tach signal indicating zero wheel movement when others are

indicating movement
:02−Tach signal indicating wheel movement when others are
indicating zero movement
:03 – Numerous Bad Pulses while moving
055−Front Wheel Tachs SYS EVENT Problem occurred with tachs on front wheel motors.
056−Inverter Software SYS EVENT Incorrect version of Inverter Software is installed. Further identified
Version by the following sub−ID:

:01−Inverter #1
:02−Inverter #2
057− Inverter 1 Software INV1 DISABLE The inverter setup is incorrect. The PSC will verify and/or change
Type Incorrect the inverters version at startup. This fault indicates that the inverter
type is incorrect and the PSC was unable to change it.
058 – Inverter 2 Software INV2 DISABLE The inverter setup is incorrect. The PSC will verify and/or change
Type Incorrect the inverters version at startup. This fault indicates that the inverter
type is incorrect and the PSC was unable to change it.
061−Motor Overspeed SYS EVENT Truck exceeded traction motor overspeed limit.

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TABLE 7. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG535 IGBT INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
063−Engine Load Signal SYS EVENT The Engine Load Signal feedback from the engine controller is out-
Fault side of limit, further defined by the following sub−ID:

:01−Analog Value below minimum value

:02−Analog Value above maximum value
:03−PWM signal failed low
:04−PWM signal failed high
:05−PWM signal failed incorrect period
:06−PWM signal inconsistent readings

Event 63 is disabled if Engine Speed based Engine Loading is ac-

tive.
065−Analog Input Range SPEED LIMIT Analog input outside its design range, further identified by the follow-
Check ing sub−ID:

b
:03−Alternator field static exciter temperature
:04−Alternator temperature
:05−Left rear wheel motor stator temperature
:06−Left rear wheel motor rotor temperature
:07−Right rear wheel motor stator temperature
:08−Right rear wheel motor rotor temperature
:09−Chopper module IGBT temperature
:10−Chopper module diode temperature
:11−Left rear wheel motor inverter IGBT temperature
:12−Left rear wheel motor inverter diode temperature
:13−Right rear wheel motor inverter IGBT temperature
:14−Right rear wheel motor inverter diode temperature
:15−Rectifier diode temperature
070−Link Capacitance SYS EVENT Link capacitance low, but acceptable for operation.
Low Caution
071−Link Capacitance SPEED LIMIT Link capacitance low, Needs to be checked.
Low Warning
072−Ground Circuit SPEED LIMIT Problem detected with ground fault detection circuit which is typically
associated with failure of the filter capacitor test to discharge the ca-
pacitors within 30 seconds.
073−Sensor Offset SYSEVENT Excessive Sensor Offset
:01−Link I Sensor
074−Inverter1 Comm INV1 DISABLE Communication attempt with Inverter #1 timed out. Inverter 1 not cut-
Failed out. Further identified by the following sub−ID:

:01−No communication Inverter #1

:02−Inverter #1 customer option bit
075−Inverter 2 Comm INV2 DISABLE Communication attempt with Inverter #2 timed out. Inverter 2 not cut-
Failed out. Further identified by the following sub−ID:

:01−No communication Inverter #2

:02−Inverter #2 customer option bit

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TABLE 7. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG535 IGBT INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
076−FB173 Card NO POWER A failure in the FB173 card was detected, further identified by the
following sub−ID:

:01−Speed FPGA did not download correctly

:02−Speed count update not changing
:03−Alternator FPGA did not download correctly
:04−Microcontroller SRAM did not program
:05−Slow task counter is less than minimum value
:06−Medium task counter is less than minimum value
:07−Fast task timer is less than minimum value
:08−FD task timer is less than minimum value
:09−Link current value is out of limits
:10−Alternator FPGA timed out
:11−uController Reset
077−Inverter Failed VI NO POWER Inverter 1 or Inverter 2 failed during VI test. System forced to link
Test discharged state. System resets and attempts test sequence again.
Does not lock out; other inverter is allowed to pass, or user can cut
out failed inverter.
078−Inverter Background SYS EVENT A failure in the inverter background communication was detected.
Communication Fail- Further identified by the following sub−ID:
ure
:01−Inverter #1
:02−Inverter #2
:03−Inverter 1 – Failed to set Options
:04−Inverter 2 – Failed to set Options
:05 –Inverter 1 – Failed to set App ID
:06 –Inverter 2 – Failed to set App Id
079−FB173 card NO PROPEL A failure in the FB173 card was detected

:09 – A3P Reading

084−Control Power SYS EVENT Loss of control power switch feedback while truck moving.
Switch

085−Hydraulic Cooling SYS EVENT Problem detected with Hydraulic blower control system, further identi-
Fault fied by the following sub−ID:

:02−Hydraulic blower motor speed signal out of range

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

:01−Propulsion system HP demand in propel mode exceeds

available engine HP for a persistent period of time
:02−Propulsion system HP demand in propel or ready mode could
result in engine stall

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TABLE 7. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG535 IGBT INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
089−Engine Speed Com- SYS EVENT Engine speed does not match engine command, further identified by
mand the following sub−ID:

:02−Allowable difference between engine command and actual

engine speed exceeded
091−Inverter 1 cutout SYS EVENT Inverter 1 is cutout.
092−Inverter 2 cutout SYS EVENT Inverter 2 is cutout.
094−Illegal Limp Mode SYS EVENT Limp Mode requested (i.e. inverter 1 or 2 cutout switch actuated)
when truck is moving.
095−Bad BRAM Battery SYS EVENT BRAM battery voltage below acceptable limit.
096−Unexpected System SYS EVENT PSC CPU reset detected without reset request.
Reset
098−Data Store SYS EVENT PSC data store commanded via PTU.
NOTE: Faults 100 − 199 as shown in 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.
100−Inverter 1 CPU Card INV 1 OFF SPEED LIM- Restrictive Inverter 1/2 CPU card problem detected.
Restrictive IT (10 MPH)
101−Inverter 1 CPU Card INV 1 OFF SPEED LIM- Non−Restrictive Inverter 1/2 CPU card problem detected.
Non−Restrictive IT (10 MPH)
102−Inverter 1 I/O Card INV 1 OFF SPEED LIM- Restrictive Inverter 1/2 I/O card problem detected.
Restrictive IT (10 MPH)
103−Inverter 1 CPU Card SYS EVENT Non−Restrictive Inverter 1/2 I/O card problem detected.
Non−Restrictive
104−Inverter 1 Fiber Op- INV 1 OFF SPEED LIM- Inverter 1/2 fiber optic card problem detected.
tic Card IT (10 MPH)
105−Inverter 1 Power INV 1 OFF SPEED LIM- Inverter 1/2 power supply card problem detected.
Supply Card IT (10 MPH)
106−Inverter 1 DC Power INV 1 OFF SPEED LIM- DC power wiring problem detected, further defined by the following
Wiring IT (10 MPH) sub−ID:

:01−DC power connection open

:02−Link and phase voltage mismatch
107−Inverter 1 Gate SYS EVENT Inverter 1/2 gate drive power supply problem detected.
Drive Power Supply
109−Inverter 1 Link Volt- INV 1 OFF SPEED LIM- Inverter 1/2 link voltage sensor problem detected.
age Sensor IT (10 MPH)
111−Inverter 1 Input Filter INV 1 OFF SPEED LIM- Inverter 1/2 input filter voltage sensor problem detected.
Voltage Sensor IT (10 MPH)
113−General Inverter 1 INV 1 OFF SPEED LIM- Inverter 1/2 phase current or voltage unbalance or exceeded limit
Restrictive IT (10 MPH) detected.
114−General Inverter 1 SYS EVENT Inverter 1/2 electrical noise detected on signal channels or operation-
Non−Restrictive al voltage limits exceeded.
115−Inverter 1/System INV 1 OFF SPEED LIM- Inverter#1/System Controller interface problem detected such as
Controller Interface IT (10 MPH) inconsistent commands, loss of communication, or sensor signals
beyond limits.

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TABLE 7. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG535 IGBT INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
116−Inverter 1 Phase A INV 1 OFF SPEED LIM- Inverter#1 Phase A problem detected such as IGBT failure to follow
IT (10 MPH) command or Phase A overcurrent.
117−Inverter 1 Phase A INV 1 OFF SPEED LIM- Restrictive Inverter#1 Phase A Positive (+) problem detected such as
Positive (+) Restric- IT (10 MPH) module failure to follow command.
tive
118−Inverter 1 Phase A SYS EVENT Non−Restrictive Inverter#1 Phase A Positive (+) problem detected.
Positive (+) Non−
Restrictive
119−Inverter 1 Phase A INV 1 OFF SPEED LIM- Restrictive Inverter#1 Phase A Negative (−) problem detected such
Negative (−) Restric- IT (10 MPH) as module failure to follow command.
tive
120−Inverter 1 Phase A SYS EVENT Non−Restrictive Inverter#1 Phase A Negative (−) problem detected.
Negative (−) Non−
Restrictive
121−Inverter 1 Phase A INV 1 OFF SPEED LIM- Inverter#1 Phase A current sensor or Phase A current problem de-
Current IT (10 MPH) tected.
123−Inverter 1 Phase A INV 1 OFF SPEED LIM- Inverter#1 Phase A voltage sensor or Phase A voltage problem de-
Voltage IT (10 MPH) tected.
125−Inverter 1 Phase B INV 1 OFF SPEED LIM- Inverter#1 Phase B problem detected such as IGBT failure to follow
IT (10 MPH) command or Phase B overcurrent.
126−Inverter 1 Phase B INV 1 OFF SPEED LIM- Restrictive Inverter#1 Phase B Positive (+) problem detected such as
Positive (+) Restric- IT (10 MPH) module failure to follow command.
tive
127−Inverter 1 Phase B SYS EVENT Non−Restrictive Inverter#1 Phase B Positive (+) problem detected.
Positive (+) Non−
Restrictive
128−Inverter 1 Phase B INV 1 OFF SPEED LIM- Restrictive Inverter#1 Phase B Negative (−) problem detected such
Negative (−) Restric- IT (10 MPH) as module failure to follow command.
tive
129−Inverter 1 Phase B SYS EVENT Non−Restrictive Inverter#1 Phase B Negative (−) problem detected.
Negative (−) Non−
Restrictive
130−Inverter 1 Phase B INV 1 OFF SPEED LIM- Inverter#1 Phase B current sensor or Phase B current problem de-
Current IT (10 MPH) tected.
132−Inverter 1 Phase B INV 1 OFF SPEED LIM- Inverter#1 Phase B voltage sensor or Phase B voltage problem de-
Voltage IT (10 MPH) tected.
134−Inverter 1 Phase C INV 1 OFF SPEED LIM- Inverter#1 Phase C problem detected such as IGBT failure to follow
IT (10 MPH) command or Phase C overcurrent.
135−Inverter 1 Phase C INV 1 OFF SPEED LIM- Restrictive Inverter#1 Phase C Positive (+) problem detected such as
Positive (+) Restric- IT (10 MPH) module failure to follow command.
tive
136−Inverter 1 Phase C SYS EVENT Non−Restrictive Inverter#1 Phase C Positive (+) problem detected.
Positive (+) Non−
Restrictive
137−Inverter 1 Phase C INV 1 OFF SPEED LIM- Restrictive Inverter#1 Phase C Negative (−) problem detected such
Negative (−) Restric- IT (10 MPH) as module failure to follow command.
tive

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TABLE 7. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG535 IGBT INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
138−Inverter 1 Phase C SYS EVENT Non−Restrictive Inverter#1 Phase C Negative (−) problem detected.
Negative (−) Non−
Restrictive
139 – Inverter 1 Phase C INV 1 OFF SPEED LIM- Inverter #1 Phase C current sensor or Phase C Current problem de-
Current IT (10 MPH) tected
141−Inverter 1 Phase C INV 1 OFF SPEED LIM- Inverter#1 Phase C voltage sensor or Phase C voltage problem de-
Voltage IT (10 MPH) tected.
143−Inverter 1 Tach 1 INV 1 OFF SPEED LIM- Restrictive Inverter#1 Tach 1 signal problem detected.
Restrictive IT (10 MPH)
144−Inverter 1 Tach 1 SYS EVENT Non−Restrictive Inverter#1 Tach 1 signal problem detected.
Non−Restrictive
145−Inverter 1 Tach 2 SYS EVENT Restrictive Inverter#1 Tach 2 signal problem detected.
Restrictive
146−Inverter 1 Tach 2 SYS EVENT Non−Restrictive Inverter#1 Tach 2 signal problem detected.
Non−Restrictive
148−Inverter 1 Chopper INV 1 OFF SPEED LIM- Inverter#1 Chopper 1 operational problem detected.
1 IT (10 MPH)
150−Inverter 1 Chopper INV 1 OFF SPEED LIM- Inverter#1 Chopper 2 operational problem detected.
2 IT (10 MPH)
151−Inverter 1 Tach Dif- INV 1 OFF SPEED LIM- Excessive difference between Inverter 1/2 Tachs 1 and 2.
ferential IT (10 MPH)
153−Inverter 1 Motor Re- INV 1 OFF SPEED LIM- Inverter 1/2 detected a motor connection problem further defined by
strictive IT (10 MPH) the following sub−ID:

:01−Motor connection open

:02−Motor connection short
164−Inv 1 Stack 2 INV 1 OFF SPEED LIM- Inverter #1, stack2 Phase A problem detected such as IGBT failure
A2+/A2− IT (10 MPH) to follow command or Phase A overcurrent
(Dual−IGBT Systems only)
165−Inv 1 Stack 2 A2+ INV 1 OFF SPEED LIM- Restrictive Inverter #1, Stack 2 Phase A Positive (+) problem de-
IT (10 MPH) tected such as module failure to follow command
(Dual−IGBT Systems only)
166−Inv 1 Stack 2 A2+ SYS EVENT Non−Restrictive Inverter #1, Stack 2 Phase A Positive (+) problem
non−restrictive detected
(Dual−IGBT Systems only)
167 Inv 1 Stack 2 A2− INV 1 OFF SPEED LIM- Restrictive Inverter #1, Stack 2 Phase A Negative(−) problem de-
IT (10 MPH) tected such as module failure to follow command
(Dual−IGBT Systems only)
168 Inv 1 Stack 2 A2− SYS EVENT Non−Restrictive Inverter #1, Stack 2, Phase A Negative (−) problem
non−restrictive detected
(Dual−IGBT Systems only)
169 Inv1 Stack 2 INV 1 OFF SPEED LIM- Inverter #1, Stack 2, Phase A Current sensor or Phase A Current
IT (10 MPH) problem detected
A2 Current
(Dual−IGBT Systems only)

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TABLE 7. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG535 IGBT INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
173 Inv 1 Phase INV 1 OFF SPEED LIM- Inverter #1, stack2 Phase B problem detected such as IGBT failure
B2+/B2− IT (10 MPH) to follow command or Phase B overcurrent
(Dual−IGBT Systems only)
174−Inv 1 Stack 2 B2+ INV 1 OFF SPEED LIM- Restrictive Inverter #1, Stack 2 Phase B Positive (+) problem de-
IT (10 MPH) tected such as module failure to follow command
(Dual−IGBT Systems only)
175−Inv 1 Stack 2 B2+ SYS EVENT Non−Restrictive Inverter #1, Stack 2 Phase B Positive (+) problem
non−restrictive detected
(Dual−IGBT Systems only)
176 Inv 1 Stack 2 B2− INV 1 OFF SPEED LIM- Restrictive Inverter #1, Stack 2 Phase B Negative(−) problem de-
IT (10 MPH) tected such as module failure to follow command
(Dual−IGBT Systems only)
177 Inv 1 Stack 2 B2− SYS EVENT Non−Restrictive Inverter #1, Stack 2, Phase B Negative (−) problem
non−restrictive detected
(Dual−IGBT Systems only)
178 Inv 1 Stack 2 INV 1 OFF SPEED LIM- Inverter #1, Stack 2, Phase B Current sensor or Phase B Current
IT (10 MPH) problem detected
B2 Current
(Dual−IGBT Systems only)
182 Inv 1 Stack 2 INV 1 OFF SPEED LIM- Inverter #1, stack2 Phase C problem detected such as IGBT failure
C2+/C2− IT (10 MPH) to follow command or Phase C overcurrent
(Dual−IGBT Systems only)
183 Inv 1 Stack 2 C2+ INV 1 OFF SPEED LIM- Restrictive Inverter #1, Stack 2 Phase C Positive (+) problem de-
IT (10 MPH) tected such as module failure to follow command
(Dual−IGBT Systems only)
184 Inv 1 Stack 2 C2+ SYS EVENT Non−Restrictive Inverter #1, Stack 2 Phase C Positive (+) problem
non−restrictive detected
(Dual−IGBT Systems only)
185 Inv1 Stack 2 C2− INV 1 OFF SPEED LIM- Restrictive Inverter #1, Stack 2 Phase C Negative(−) problem de-
IT (10 MPH) tected such as module failure to follow command
(Dual−IGBT Systems only)
186 Inv1 Stack 2 C2− SYS EVENT Non−Restrictive Inverter #1, Stack 2, Phase C Negative (−) problem
non−restrictive detected
(Dual−IGBT Systems only)
187 Inv 1 Stack 2 C2 INV 1 OFF SPEED LIM- Inverter #1, Stack 2, Phase C Current sensor or Phase C Current
Current IT (10 MPH) problem detected
(Dual−IGBT Systems only)
601−TCI CPU Card NO PROPEL A problem was detected with the TCI CPU card software. Reset
FB144/FB174 Faults. If they reappear this event points to a CPU card issue. If
they only appear immediately after applying power, it points to a low
BBRAM battery.,
602−FB104 TCI Digital NO PROPEL A problem was detected with the TCI digital I/O card.
I/O Card

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TABLE 7. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG535 IGBT INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
603−FB160 TCI Analog NO PROPEL A problem was detected with the TCI analog I/O card.
I/O Card
604−TCI to PSC RS422 SPEED LIMIT Serial link communication with PSC was lost for a persistent time
Comm period.
607−Positive 5 volts SPEED LIMIT +5V Power Supply exceeded limits for a persistent period of time.
608−Positive 15 Volts SPEED LIMIT +15V Power Supply exceeded limits.
609−Negative 15 Volts SPEED LIMIT −15V Power Supply exceeded limits.
610−Pot Reference SPEED LIMIT Pot Reference exceeded limits.
613−Analog Input SPEED LIMIT An analog signal input on the analog I/O card exceeded its limits for
a persistent period of time, as defined by the following sub−ID:

:01−Ground (A2D)
:02−Gain Check (A2D)
616−Simultaneous For- NO PROPEL Simultaneous receipt of forward and reverse direction commands.
ward and Reverse
Command
617−Engine Start Re- SYS EVENT The engine start request was denied for the following reason defined
quest Denied by the sub−ID:

:01−Engine warning signal received during cranking

:02−Engine Kill signal received during cranking

Event only active if cranking is controlled by GE.

619−Engine Warning NO PROPEL The engine warning signal was received when the engine speed is
above the run threshold.
620−Engine Kill while NO PROPEL The engine kill signal was received while the truck was moving.
Moving
622−Park Brake NO PROPEL Unexpected park brake operation defined by the following sub−ID:

:01−Park brake command and feedback do not agree

:02−Park brake set feedback received while truck moving

624−Body Up and Pay- NO PROPEL Simultaneous receipt of both full payload and body up signals for a
load Indication persistent time period.
625−Body Up with truck SYSEVENT Body up signal active with truck speed +5mph over dump body up
Speed speed limit.
626−Load Brake while SYSEVENT The Load Brake was applied while the truck was moving faster then
moving 8mph.
628−Battery Voltage Out SYSEVENT Battery voltage as measured by the TCI analog card is out of limit
of Limit defined by the following sub ID:
:01−Battery voltage low (<20Vdc)
:02−Battery voltage high (>34Vdc)

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TABLE 7. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG535 IGBT INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
629−Barometric Pres- SYS EVENT Barometric pressure sensor signal exceeded limits for a persistent
sure period of time, further defined by the following sub−ID:

:01−Barometric pressure sensor value too low

:02−Barometric pressure sensor value too high
630−Axle Box Pressure SPEED LIMIT Axle Box pressure signal exceeded limits, indicating a problem with
the sensor, duct work, or axle box sensor. Further defined by the
following sub−ID:

:01−No cooling air

:02−Low voltage (Analog sensor only)
:03−High voltage (Analog sensor only)
:04−Sensor reversed (Digital sensor only)
:05−Sensor High with Engine Off (Digital sensor only)
631−Ambient Tempera- SYS EVENT Ambient temperature sensor signal exceeded limits for a persistent
ture period of time, further defined by the following sub−ID:

:02−Ambient temperature signal too high

632−TCI Configuration NO PROPEL A problem with the TCI configuration file has been detected, further
File defined by the following sub−ID:

:01−File not loaded

:02−File loaded improperly, resulting in bad CRC
:03−Wrong version of file loaded
633−BBRAM Battery SYS EVENT Battery−backed RAM (BBRAM) battery has failed.
Failure
634−Truck Overloaded NO PROPEL Truck operation restricted when overloaded signal received and TCI
Restrictive configured for restrictive response.
638−Engine cranking SYS EVENT The diesel engine was cranking longer than the maximum allowed
timeout cranking time.
639−Engine Start Re- SYS EVENT An Engine Start Request was received while the diesel engine was
quest While Running 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.
640−Accel Pedal Too NO PROPEL Accelerator Pedal input is greater than the maximum value for a spe-
High cified period of time.
641−Accel Pedal Too SYS EVENT Accelerator Pedal input is less than the minimum value for a speci-
Low fied period of time.
642−Engine Cranked Us- SYS EVENT The Engine was cranked by overriding the Engine Cranking Protec-
ing Override tion.
643−Control Group Air SPEED LIMIT Control Group blower pressure signal exceeded limits, indicating a
problem with the sensor, duct work, or control box sensor. (This sen-
sor is optional). Further defined by the following sub−ID:

:01−No cooling air

:02: Sensor High with Engine Off
644 – Cabinet Heater SYS EVENT An error has been detected with the control cabinet heater circuit

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TABLE 7. (Cont’d) EVENT CODE DESCRIPTIONS AND INFORMATION

(CONTROL GROUP 17KG535 IGBT INVERTERS)
Event Event Restrictions
Detection Information
Description (If Any)
650−Pedal Calibration SYS EVENT The Pedal calibration is incorrect and needs to be redone.

:01 – Accel Pedal

:02 – Retard Pedal or Lever
:03 – Full HP not Reached
:04 – Startup Calibration Needed
651 Truck ID SYS EVENT Truck ID is zero. Truck ID needs to be set
652 DID Panel SYS EVENT DID panel setup options are incorrect in configuration file.
696−Unexpected CPU SYS EVENT The TCI CPU was reset while the system was in Self Load, Propel,
Reset Retard, or Ready mode.
698−PTU Data Store SYS EVENT The DATASTORE command was received by the TCI. No corrective
action required.
However, if DATASTORE was not commanded and the event was
logged, check DATASTORE switch and wiring.

10. SPECIAL OPERATIONS AND TESTS

10.1. WELDING ON THE TRUCK

When welding on trucks equipped with GE control panels, connect the welder’s ground cable such that welding
current does not flow through the truck’s control 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.

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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 Park Brake and place the propulsion system in REST
mode by placing the Park Brake and REST rocker switches in the ON position 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. Remove the load, if present, from the truck.

3. On KG498 systems, move the affected inverter cutout switch to the CUTOUT position. Inverter cutout
switches are located behind the maintenance panel access door on the cab end side of the KG498 control
group. On KG526 systems, cut out the affected inverter using the DID Panel. This will disable that
inverter/wheel motor combination from either accelerating or retarding the truck.

4. Release the Park Brake and exit propulsion system REST mode by placing the Park Brake and REST rocker
switches in the OFF position.

5. Place the Direction Selector handle in FORWARD and move the truck to the desired location.

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 Low Voltage Connector
VH1 CN1−5
VH2 CN1−6
VH3 CN1−10
VH4 CN1−14
VH5 CN1−7
VH6 CN1−3
VH7 CN1−2
VH8 CN1−1

VAM1 AND VAM2, 17FM681, 5 CHANNELS

High Voltage Stud Low Voltage Connector
VH1 CN1−1
VH2 CN1−2
VH3 CN1−3
VH4 CN1−4
VH5 CN1−5

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10.3.1. A3PV Panel Check (KG498 Only)

1. Connect a jumper wire from the load side of the BATFU fuse located near the bottom of the left side wall of the
left control cabinet to terminal A on A3PV.

2. Connect a jumper wire from the cabinet ground to terminal C on A3PV.

3. With an applied battery voltage of 24 V DC, the A3PV panel output measured between terminals D and F
should be 0.12 V DC (200:1 scaling). If the reading is significantly different from this value, replace the A3PV
and repeat this check.

4. If the A3PV panel output checks OK, remove the jumper wires previously installed in this procedure.

10.3.2. LINKV Panel Check (KG498 Only)

1. Connect a jumper wire from the load side of the BATFU fuse located near the bottom of the left side wall of the
left control cabinet to terminal A on LINKV.

2. Connect a jumper wire from the cabinet ground to terminal C on LINKV.

3. With an applied battery voltage of 24 V DC, the A3PV panel output measured between terminals D and F
should be 0.12 V DC (200:1 scaling). If the reading is significantly different from this value, replace the LINKV
and repeat this check.

4. If the LINKV panel output checks OK, remove the jumper wires previously installed in this procedure.

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 Between + and − : greater than 20 Kohm
S Between M and + : greater than 1 Megohm
S Between M and − : greater than 1 Megohm

10.5. LINK CAPACITANCE TEST MONITORING

The main propulsion DC link capacitance test can be performed through the DID panel (refer to Section 8.4.3.,
LINK CAPACITANCE TESTING) provided that truck conditions permit this test. Those conditions are as follows:

1. Engine running and DC link charged.

2. 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. 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.

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2. From the window browser, select PTU Screens −> PSC −> Normal_Operation −> Tests −> Capacitance
Test (Figure 93).
3. The Capacitance Test screen is now displayed and the test data can be viewed (Figure 94).

4. Close the Capacitance Test display screen by clicking on the X in the upper right corner of the screen.

5. 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.

E−44403

Figure 93. PSC Capacitance Test Screen Assess Sequence.

E−44404

Figure 94. Capacitance Test Screen.

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10.6. AUXILIARY INVERTER SCR/IGBT TROUBLESHOOTING (KG498

CONTROL GROUPS ONLY)

Use the following procedure to determine whether or not the auxiliary inverter SCRs and/or IGBTs have failed.

NOTE: Refer to GEK−91718, Auxiliary Inverter Panel For 320 Ton OHV AC Troubleshooting and Repair,
for additional troubleshooting procedures and SCR/IGBT replacement procedures.

WARNING: Ensure that all power is removed from the AC OHV propulsion system prior to performing this
procedure. This includes checking that both the propulsion inverter filter capacitors as well as the
auxiliary inverter filter capacitors are fully discharged. Failure to do so may result in personnel injury or
death.

10.6.1. Preparation
1. Disconnect the auxiliary inverter input power connections at PH+, PH−, IV+ and IV−.

2. Disconnect the auxiliary inverter motor output connections at AM101, AM201 and AM301.

3. Disconnect the following connectors from the Auxiliary Inverter Circuit Card: J1, J2, J3, J4, J6, J7, J8, J10, J11,
J12, J13, J14, J15 and J16.

10.6.2. SCR Check−Out

1. Using a hand−held volt−ohmmeter (VOM), measure the resistance between pins 1 and 2 of connector J10.
The nominal value should be between 10 and 20 ohms. A resistance reading of less than 2 ohms or greater
than 100 ohms indicates that the associated SCR has failed.

2. Repeat the above resistance measurement for connectors J11, J12, J14, J15 and J16.

3. Using a hand−held VOM, measure the Anode−to−Cathode and Cathode−to−Anode resistance measurement
for all six (6) SCRs. The nominal value should be greater than 200 Kohm. A resistance reading of less than 100
ohms indicates that the associated SCR has failed.

10.6.3. IGBT Check−Out

1. Using a hand−held volt−ohmmeter (VOM), measure the resistance between pins 1, 2 and 3 of connector J1.
The nominal value should be greater than 200 Kohms between any combination of pins. A resistance reading
of less than 100 ohms between any two points indicates that the associated IGBT has failed.

2. Repeat the above resistance measurement for connectors J2, J3, J4, J7 and J8.

3. Reconnect all connections that were disconnected in steps 1, 2, and 3.

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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. Use the wPTUt Manual Test Screen to turn on the Gate Driver Power Supply (GDPS) of the
relevant inverter. (Refer to Section 6.7. for procedures.)

2. Run the Inverter VI Test as follows to determine if the fault occurs again:

a. Apply the Park Brake and place the propulsion system in REST mode by placing the Park Brake and REST
rocker switches in the ON position and place the Direction Selector handle in the NEUTRAL position.

b. Start and run the engine.

c. When the engine has achieved its idle speed, release the Park Brake and exit propulsion system REST
mode by placing the Park Brake and REST rocker switches in the OFF position.

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.

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 GTO 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.

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b. If the red LED is OFF, that is usually an indication that the GTO on the phase module is shorted or the gate
driver has failed.

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.

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 KHz 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 GTO test OK, but the truck has a recent history of repeated failures, replace the phase
module.

6. Inspect all laminated bus bars for damage.

7. Use a volt−ohm 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.

8. Inspect all other phase modules for flash burns.

12. 17FB144 AND 17FB147 CIRCUIT CARD TROUBLESHOOTING GUIDE

12.1. INTRODUCTION

Often, 17FB144 and 17FB147 boards used in 320 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 selftest or EPROM checksum error.
OFF – No condition met for ON state.

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The LED indicators flash during boot−up and can flash if no program is installed in the CPU board. LEDs can also
flash if the 5 V Power Supply is low. Normally, the CPU board is functional and can be communicated with, or
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 8.

12.3. TROUBLESHOOTING PROCEDURE

Figure 95 shows the troubleshooting flow chart for both 17FB144 and17FB147 boards.

The flow chart references other figures to provide details where necessary.

TABLE 8. TYPICAL 17FB144 AND 17FB147 BOARD LED PATTERNS

FOR VERSION 20 AND LATER SOFTWARE
BOARD OTHER
PRO- CPU
GRAMMED BOARD
(PROGRAM PRO-
BOARD PROB- IN FLASH GRAM−
CONDITION LEM MEMORY)? MED? 17FB144 BOARD 17FB147 BOARD
WDTIME LIGHT FATL WDTIME LIGHT FATL
LIGHT LIGHT
1 Running / Major failure xx xx xx ON solid xx ON solid
Power−up
2 Running / 5V power 1 sup- xx xx ON solid or 2 ON solid or 2 ON solid or 2
Power−up ply low flashing flashing flashing
3 Running None / Onboard Yes xxx OFF OFF OFF OFF
battery low 3
4 Running None / Onboard No Yes OFF or 4 OFF or 4 OFF or 4 OFF or 4
battery low 3 1. Flash twice 1. xxx 1. Flash twice 1. xxx
2. Flash 2. Flash 2. Flash 2. Flash
3. 1 sec. delay 3. xxx 3. 1 sec. delay 3. xxx
4. Flash 4. xxx 4. Flash 4. xxx
5. Repeat after 5. Repeat after 5. Repeat after 5. Repeat after
variable variable variable variable
time delay time delay time delay time delay
5 Running None / Onboard No No OFF OFF OFF OFF
battery low 3
6 Power−up None / Onboard Yes xx 1. Flash 1. Flash 1. Flash 1. Flash
battery low 3 2. 1 sec. delay 2. 1 sec. delay
3. Flash 3. Flash
4. 3 sec. delay
5. Flash twice
7 Power−up None / Onboard No xx 1. Flash 1. Flash 1. Flash 1. Flash
battery low 3 2. 1 sec. delay 2. 1 sec. delay
3. Flash 3. Flash

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TABLE 8. (Cont’d) TYPICAL 17FB144 AND 17FB147 BOARD LED PATTERNS

FOR VERSION 20 AND LATER SOFTWARE
BOARD OTHER
PRO- CPU
GRAMMED BOARD
(PROGRAM PRO-
BOARD PROB- IN FLASH GRAM−
CONDITION LEM MEMORY)? MED? 17FB144 BOARD 17FB147 BOARD
WDTIME LIGHT FATL WDTIME LIGHT FATL
LIGHT LIGHT
8 Power−up None but serial xx xx Flash once only, Flash once only, Flash once only, Flash once only,
with PTU com cable prob- then OFF then OFF then OFF then OFF
attached lem between
board and PTU
5

NOTE: Voltages listed are approximate.

1– Measure voltage between TP4 – WDDIS and TP2 – GND on either the 17FB144 or 17FB147 board.
Reading should be at least 4.95 V.
2– Lights will be on solid for TP4 – WDDIS to TP2 – GND voltages below 4.9 V. Above 4.9 V to 4.95 V, 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 – Light pattern can vary per board as well as if the wPTUt (PC) is connected to the relevant board serial port.
5 – Open wPTUt serial communication ground wire with wPTUt connected can cause board boot−up (buck)
routine to not run during power−up.

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 boot−up text that can be used to determine if communications with the CPU are active, the CPU board has
passed self tests, whether software 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 boot−up 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 re−enabling it at the window shown in Figure 96. If this does not work, reboot the
computer.

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Refer to Sheet 2 of 2 E−44732

Figure 95. 17FB144 And 17FB147 Board Troubleshooting Procedure (Part 1 of 2).

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

Refer to Sheet 1 of 2

E−44732

Figure 95. 17FB144 And 17FB147 Board Troubleshooting Procedure (Part 2 of 2).

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 Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems, GET−6864B

Should say this if com port is OK

E−44733

Figure 96. COM1 Serial Port Window Message for Proper Operation.

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.

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 (refer to Figure 97).

NOTE: HyperTerminal can also be accessed from the wPTUt login window by selecting the Terminal
Emulator Mode radio button (Figure 4).

2. The window shown in Figure 98 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.

3. The Connect To window shown in Figure 99 will appear. Select Direct to Com1 in the Connect using menu
selection and then click OK.

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Double click here

E−44734 E−44735

Figure 97. Hyperterminal Icon. Figure 98. Hyperterminal New Connection

Window.

E−44736 E−44737

Figure 99. Hyperterminal Connect to Window. Figure 100. Hyperterminal COM1

Properties Window

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Banner shows “Connected”

and counts connection time

E−44738

Figure 101. Hyperterminal Main Window When Connected to COM1 Port.

4. The COM1 Properties window shown in Figure 100 will appear. Select the following and then click OK.
(Advanced settings do not need to be adjusted):
S Bits per second = 9600 (Default = 2400)
S Data bits = 8 (Default)
S Parity = None (Default)
S Stop bits = 1 (Default)
S Flow control = None (Default = Hardware)
5. After the COM1 properties are set, the main HyperTerminal window will look like that shown in Figure 101, 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 102. If this happens, try to reset the COM1 port by
disabling it and re−enabling it at the window previously shown in Figure 96. If this does not work, reboot the
computer.

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

Message window

Banner shows “Disconnected”

E−44739

Figure 102. Hyperterminal Main Window When Not Connected to COM1 Port.

7. Once HyperTerminal is connected to the COM1 port, cycle control power to the connected CPU board. The
screen will appear as shown in Figure 103 if the CPU board is already programmed and running. Only the
17FB144 board will show the text line pertaining to the battery test. Figure 103 shows the HyperTerminal main
window scrolled backwards 1 line to show the complete text that comes out of the CPU board.

NOTE: The HyperTerminal screen shows a white background for text that is in the latest window. If the
window is scrolled backwards, the background 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 104 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.

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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.

E−44740

Figure 103. Hyperterminal Main Window After Cycling Control Power, Program Installed and Running.

9. To erase the flash memory (program) on a CPU board, the boot−up 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 105.

10. After the boot−up 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 106 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 boot−up
(buck) routine to not run during power−up. If this happens, the text in HyperTerminal will stop after the 25MHZ
board detected message as shown in Figure 107.

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
set−up.

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.

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

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.

E−44741

Figure 104. Hyperterminal Main Window After Cycling Control Power, Program Not Installed.

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Hold TAB key down until

this message appears
while cycling power.

E−44742

Figure 105. Hyperterminal Main Window After Cycling Control Power, With Tab Key Held Down
(Interrupting Boot−Up Routine).

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GET−6864B, Vehicle Test, Diagnostic, and wPTUt Instructions For GE320AC OHV Propulsion Systems

Type in “ef” and hit Enter.

Characters may show up to
the far right of the =>.

Flash memory successfully erased

E−44743

Figure 106. Hyperterminal Main Window After Erasing CPU Board Flash Memory.

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E−44744

Figure 107. Hyperterminal Main Window When Boot−Up (Buck Routine) Does Not Run Dut to Open
PTU Serial Cable Ground Wire With the PTU Connected.

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13. GLOSSARY OF TERMS

Listed in TABLE 9 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 9. GLOSSARY
Term Description
AFSE Alternator Field Static Exciter panel regulates the current in the alternator field.
AFSER Alternator Field Static Exciter Resistor facilitates battery boost to AFSE. AFSER is used in
the low side driver circuit.
ALT Alternator is a salient–pole, three–phase, Y–connected, AC machine that is mounted solid-
ly to the diesel engine and is driven by the engine crankshaft. The alternator provides elec-
trical power for propulsion and control systems.
AMBTS Ambient Temperature Sensor senses ambient air temperature (located in the contactor
area).
ANALOG I/O CARD PSC Analog Input/Output Card provides signal conditioning for analog signals to/from the
(PSC) Propulsion System Control. This card monitors system voltages and currents along with
frequency input from the engine speed sensor. It also contains the digital alternator field
regulator control.
ANALOG I/O CARD TCI Analog Input/Output Card provides signal conditioning for analog signals to/from the
(TCI) Truck Control Interface. This card monitors signals from sensors located throughout the
truck and provides driving signals for operator cab meters.
A3PV Alternator Three−Phase Voltage Measuring Module (17FM681) attenuates the high volt-
age from two phases of the Alternator to a level acceptable to the electronics on the Analog
I/O Card, located in the Propulsion Control Panel.
BAROP Barometric Pressure Sensor provides a barometric pressure signal to the control system
used in the calculations of control system cooling requirements.
BATFU Battery Power Fuse provides overload protection to the control equipment.
BATTSW OEM supplied Battery Switch is used to connect/disconnect battery voltage from the truck
control equipment.
BD1 Battery Blocking Diode provides isolation between the Battery Line Filter output voltage
and truck battery voltage.
BFC Battery Filter Capacitor Assembly is used to temporarily sustain control power to the elec-
tronics panels in the presence of battery voltage dips and outages.
BFCR* Battery Filter Capacitor Resistor is used to limit inrush current to the Battery Filter Capaci-
tor.
Blower Motors #1 and #2 (5GY19) are DC motors located within the Dynamic Retarding
Assembly. The motors drive two blowers (fans) each. The blowers provide cooling air for
BM1 the Retarding Resistors in the Dynamic Retarding Assembly during dynamic retarding op-
erations and self−load testing.
BM1I* Grid Blower Motors #1 and #2 Current Measuring Modules (LEM) is used to measure the
DC current flow through the grid blower motors.

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TABLE 9. (Cont’d) GLOSSARY

Term Description
CCF1, CIF11A, Inverter #1 Filter Capacitors store the Inverter #1 DC bus voltage to provide instantaneous
CIF11B, CIF12A, power when the Inverter1 IGBT Phase Modules first turn on.
CIF12B
CCF2, CIF21A, Inverter #2 Filter Capacitors store the Inverter #2 DC bus voltage to provide instantaneous
CIF21B, CIF22A, power when the Inverter2 IGBT Phase Modules first turn on.
CIF22B
CCL1, CCL2 Capacitor Charge Indicating Lights #1 and #2 are illuminated when 50 volts or more is pres-
ent on the DC link (the DC bus that connects the Alternator output, Chopper Module/Resis-
tor Grid circuits, and traction Inverters).
CCLR1, CCLR2 Capacitor Charge Resistor Panels #1 and #2 are connected across the DC link to provide a
voltage attenuated sample of the DC link voltage to the Capacitor Charge Indicating Lights.
CD1, CD2 IGBT Chopper Diodes #1 and #2 (IGBT, 17FM796 on KG535 Control Group).
CF1, CF2 Chopper Module Fuses. Two fuses in parallel per Chopper Module.
CGBM1, CGBM2* Blower Motor di/dt Reduction Capacitors are used to limit the rate of current change in the
retard grid blower motor circuit.
CMAF Alternator Field Current Sensor (LEM) detects the amount of current flow through the Alter-
nator field winding.
CMT Alternator Tertiary Current Sensing Module (LEM) detects the amount of AFSE current
supplied by the Alternator tertiary winding.
CM1, CM2 IGBT Chopper Modules #1 and #2 (IGBT, 17FM797 on KG535 Control Group) control the
DC voltage applied to the grid resistors during retarding operations.
CM11A, CM11B, Phase 11A/12A, 11B/12B and 11C/12C Current Sensing Modules (LEM) detect the
CM11C, CM12A, amount of current flow through the A, B and C phases of Traction Motor #1.
CM12B, CM12C
CM21A, CM21B, Phase 21A/22A, 21B/22B and 21C/22C Current Sensing Modules (LEM) detect the
CM21C, CM22A, amount of current flow through the A, B and C phases of Traction Motor #2.
CM22B, CM22C
CNX1, CNX2, CNX3, Control Group Canon Plug Connectors for external control wiring interface connections.
CNX4, CNX5
CPR 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.
CPRD Control Power Blocking Diode provides diode blocking between the control power switch
input and the control power digital output.
CPRS CPR Suppression Module limits the transient voltage induced into the battery system
whenever power to the CPR coil is interrupted.
CPS Control Power Switch (mounted on the diagnostic panel) is used to connect/disconnect
battery voltage to/from the control system.
CPU CARD (PSC) System CPU Card (17FB174) provides propulsion control system processing and serial
link communication.

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TABLE 9. (Cont’d) GLOSSARY

Term Description
CPU CARD (TCI) System CPU Card (17FB174) provides the processing of truck systems I/O and serial link
communication.
DID Diagnostic Information Display (17FM558) provides operator/maintenance personnel with
the ability to monitor the operational status of certain truck systems and perform system
diagnostic tests.
DIGITAL I/O CARD System Digital Input/Output Card (17FB104) provides battery−level drive signals to control
(PSC) relays, contactors and LEDs; and receives battery−level status feedbacks of relays, con-
tactors and switches.
DIGITAL I/O CARD System Digital Input/Output Card (17FB104) provides battery−level drive signals to control
(TCI) relays, contactors and lights; and receives battery−level status feedbacks of relays, con-
tactors and switches.
ESS Engine Speed Sensor that is mounted on the alternator, which is directly coupled to the
engine.
F11A1, F11A2, Inverter #1 Phase Fuses. Used to protect cabling/busbars in the event of a “shoot through”
F11B1, F11B2, (short from DC Link Positive to DC Link Negative). Two fuses in parallel per Phase.
F11C1, F11C2,
F12A1, F12A2,
F12B1, F12B2,
F12C1, F12C2
F21A1, F21A2, Inverter #2 Phase Fuses. Used to protect cabling/busbars in the event of a “shoot through”
F21B1, F21B2, (short from DC Link Positive to DC Link Negative). Two fuses in parallel per Phase.
F21C1, F21C2,
F22A1, F22A2,
F22B1, F22B2,
F22C1, F22C2
FDR Filter Discharge Resistor Panel is a resistor divider connected across the DC link. FDR
discharges the DC link.
FODC1, FODC2 Fibre Optic Display Card provides voltage and noise isolation for the control and feedback
signals between the Propulsion Control Panel and the Phase/Chopper Modules.
FP Filter Panel (17FM460) is connected across the three−phase output of the Alternator to
filter electrical noise.
GDPC1, GDPC2 Gate Drive Power Converter provides gate drive power for IGBT phase and chopper mod-
ules.
GF Generator (Alternator) Field Contactor connects the AFSE to the Alternator field. GF is
controlled by the Propulsion Control Panel.
GFCO GF contactor cut−out switch provides a means of mechanically preventing energization of
the GF contactor, thereby providing a means to ensure that the DC link is not energized.
GFM Gate Firing Module receives the incoming pulses from the Analog Input/Output Card in the
Propulsion Control Panel, converts them into appropriate AFSE control signals.
GFR Generator Field Relay (17LV66) picks up with the GF contactor and is used for alternator
field control.
GFRS GFR Suppression Module limits the transient voltage induced into the battery system
whenever power to the GFR coil is interrupted.

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TABLE 9. (Cont’d) GLOSSARY

Term Description
GFS GF Suppression Module limits the transient voltage induced into the battery system when-
ever power to the GF coil is interrupted.
GRR Ground Reference Resistor Panel is a voltage divider connected across the DC link, used
with GRR9 and GRR10 to detect system ground faults.
GRR9 GRR9 is used in conjunction with GRR and GRR10 to measure ground fault current.
GRR10 GRR10 is used in conjunction with GRR and GRR9 to measure ground fault current.
Integrated Control Panel (17FL386) containing all functions formerly provided by the sepa-
rate PSC and TCI panels.
ICP
INV1 TMC CARD Inverter #1 Traction Motor Control (TMC) Card (17FB179) controls Inverter 11/12 Phase
Modules and Chopper Modules by default.
INV2 TMC CARD Inverter #2 Traction Motor Control (TMC) Card (17FB179) controls Inverter 21/22 Phase
Modules and Chopper Modules when Inverter 1 is cutout/disabled.
KEYSW OEM supplied Keyswitch is used to connect/disconnect battery voltage to/from CPR.
LINKI Link Current Sensing Module (LEM) 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).
PM11A+, PM11B+, Phase Modules (IGBT, 17FM796 on KG535 Control Group) provide the positive driving
PM11C+, PM12A+, voltages for each of the three windings of Traction Motor #1.
PM12B+, PM12C+
PM11A−, PM11B−, Phase Modules (IGBT, 17FM797 on KG535 Control Group) provide the negative driving
PM11C−, PM12A−, voltages for each of the three windings of Traction Motor #1.
PM12B−, PM12C−
PM21A+, PM21B+, Phase Modules (IGBT, 17FM796 on KG535 Control Group) provide the positive driving
PM21C+, PM22A+, voltages for each of the three windings of Traction Motor #2.
PM22B+, PM22C+
PM21A−, PM21B−, Phase Modules (IGBT, 17FM797 on KG535 Control Group) provide the negative driving
PM21C−, PM22A−, voltages for each of the three windings of Traction Motor #2.
PM22B−, PM22C−
PS Power Supply (17FH41) which provides +5VDC, ±15VDC, ±24VDC regulated voltage.
PSC Propulsion System Controller (17FB174) is one of the CPU cards.
R1 Battery Boost Resistor limits surge current in the Alternator field circuit when the GFR con-
tacts initially close.
RDA, RDB, RDC Rectifier Diode Panel, also denoted as the main rectifier panel, converts the output three−
phase, AC voltage from the Alternator to DC voltage to power the two Inverters. RD is three
separate panels (RDA, RDB, RDC).
RG1A, RG1B, RG1C, Grid Resistors dissipate power from the DC link during retarding, self−load, and Inverter
RG1D, RG2A, RG2B, Filter Capacitor discharge operations. 14 Resistor Grids for KG535 Control Groups.
RG2C, RG2D, RG3A,
RG3B, RG3C, RG4A,
RG4B, RG4C

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TABLE 9. (Cont’d) GLOSSARY

Term Description
RGBM1, RGBM2 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.
RP1, RP2 Retard Contactors 1, and 2 (41A296327ALP2), when closed, connect the Grid Resistors to
the DC link during retarding, self−load, and Inverter Filter Capacitor discharge operations.
RP1S, RP2S RP1 and RP2 Suppression Modules limit the transient voltage induced into the battery sys-
tem whenever power to the RP1 or RP2 coil is interrupted.
SS1, SS2 Traction Motor Speed Sensors which provide Traction Motor speed signals to the respec-
tive Inverter control cards.
SS3, SS4 Front Wheel Speed Sensors. Front Wheel Speeds are monitored for wheel slips/slide con-
trol logic.
TCI Truck Control Interface (17FB174) is a CPU card.
TH1 Alternator Field Thyrite (Varistor) protects the Alternator field circuit from voltage tran-
sients.
TM1, TM2 Motorized Wheels 1 (Left hand side looking forward) and 2 each consisting of a Traction
Motor and a Transmission Assembly. The three−phase asynchronous Traction Motors
convert electrical energy into mechanical energy. This mechanical energy is transmitted to
the wheel hub through the speed reducing Transmission Assembly.
VAM1, VAM2 Voltage Attenuation Modules #1 and #2 (17FM702) are eight−channel devices for the in-
verters. 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.
VAM3, VAM4 Voltage Attenuation Modules #3 and #4 (17FM681) are five−channel devices for system
use. VAM3 and VAM4 are used to attenuate high voltages to a level acceptable to the con-
trol electronics.

14. SOFTWARE VERSIONS

14.1. VERSION 21, DECEMBER 2005

Version 21 was developed to support the 17KG535 and 17KG537 Control Group based GETS OHV AC propulsion
systems.

Version 21 software is for the 17FL386 Propulsion System Controller panel and a portable PC. It may be applied to
17KG526xx, 17KG527xx, 17KG531xx, 17KG535xx, and 17KG537xx Control Groups of GETS OHV AC propulsion
systems.

Version 20 includes all application software for the control system panels as well as the MS−Windows based PTU
(wPTUt) listed in TABLE 10.

NOTE: Version 20 should not be applied to 17KG498 Control Groups without the specific approval of
GETS OHV engineering.

General information for version 20 and previous versions of software is listed in TABLE 12. Refer to the SMI#
shown in the table for specific information.

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TABLE 10. VERSION 20 SOFTWARE

Software Name Version Software Location
On Truck Controller Software
Propulsion System Controller (PSC) 21.00b 17FB147 or 17FB174
Card
Truck Control Interface (TCI) 21.00b 17FB144 or 17FB174
Card
Inverter – 17FB138 01.xx.24.10 17FB138 Card
Inverter – 17FB172 05.xx.24.10 17FB172 Card
Inverter – 17FB179 06.xx.24.10 17FB179 Card
wPTUt Toolbox (Release 3.0)
AC PTU 21.00 Laptop
AC Mine and OEM Configuration Utility 21.00 Laptop
OHV Download Utility 3.01 Laptop
OHV Data−logger Utility X18, Sept 2002 Laptop
DC PTU 2.00 Laptop
DC Mine and OEM Configuration Utility 2.00 Laptop
pocketPTUt
AC pocketPTUt 2.0 Pocket PC
DC pocketPTUt 1.0 Pocket PC

14.2. VERSION 19, JULY 2002

Version 19 was developed to support end−user and OEM requests as well as addressing reliability improvements
and product enhancements to the GE propulsion system.

Version 19 software is for the 17FL320 Propulsion System Controller panel, the 17FL349/17FL373 Truck Control
Interface panel, or the 17FL375 Integrated Control Panel, and a portable PC. It may be applied to all GETS OHV AC
propulsion systems, including the 17KG498xx, 17KG526Bx, and 17KG527xx groups.

Version 19 includes all application software for the control system panels as well as the MS−Windows based PTU
(wPTUt) listed in TABLE 11.

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 12. Refer to the SMI#
shown in the table for specific information.

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TABLE 11. VERSION 19 SOFTWARE

Software Name Version Location
Controller Software
Propulsion System Controller (PSC) 19.03a 17FL320 or 375
Truck Control Interface (TCI) 19.03a 17FL349, 373, or 375
Inverter − IMC Version (17FB138/17FB134) 02.19.03 17FL320
Inverter − TMC Version (17FB172) 05.19.03 17FL320 or 375
Windows PTU and toolbox (Release 1.0)
AC PTU 19.03 PC
AC Mine and OEM Configuration Utility 19.03 PC
OHV Download Utility 2.0 PC
OHV Datalogger Utility X16, July 2001 PC
OHV Datalogger Graphing Utility B6.4 PC
FB173 Card Software (17FL375 Panel Only)
17FB173 Card − CPLD Version (17KG526, 527 Only) 3 or Higher 17FB173 Card
Software Name Version Location
17FB173 Micro−Controller Software (17KG526, 527 2.42 17FB173 Card
Only)
17FB173 Alternator Field Programmable Gate Array 3.2, 01/28/01 17FB173 Card
(FPGA) (17KG526, 527 Only)
17FB173 Speed FPGA (17KG526, 527 Only) 7.3, 09/26/00 17FB173 Card

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14.3. PREVIOUS VERSIONS INFORMATION

TABLE 12. SOFTWARE VERSIONS INFORMATION

Version Date Released GETS SMI # Status Notes
21 December 2005 41A322501BF Active Current version for propulsion sys-
tem control groups 17KG526, 527,
531, 535, 537; includes support for
wPTUt. No previous versions sup-
ported GE200AC.
20 March 2003 41A322501BE Active Current version for propulsion sys-
tem control groups 17KG526, 527,
531; includes support for wPTUt
19 July 2002 41A322501BD Obsolete Current version for all propulsion
system models; includes support for
wPTUt
18 May 2001 41A322501BC Obsolete Added support for KG526 and
KG527 groups
17 August 1999 41A322501BB Obsolete General improvements
16 October 1998 41A322501BA Obsolete General improvements
14 June 1998 N/A Obsolete Added support for high altitude op-
eration
13 October 1997 N/A Obsolete Added support for Tar Sands opera-
tion
12 September 1997 N/A Obsolete First official version for KG498
groups

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GE Transportation
Systems
2901 East Lake Road
NEW 09/00, FSB Erie, Pennsylvania 16531
REV 05/03, REB
PRINTED
REV 05−2007, MKW/PAB IN
U.S.A.
E

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