Model 4700

Maintenance Manual

Section 6.Messages and Codes

Fault Codes

Refer to the “Pinout Matrix” located in Theory of Operation section for all voltage and resistance values and component interconnection.

Code Description

01 Code 01: Master TPA Internal Fault

The power amplifier has detected an internal fault.

02 Code 02: Master TPA Internal Fault

Fault in the area of memory in which the adjustment parameters are stored.

03 Code 03: Master TPA Internal Fault

The power amplifier has detected an internal fault.

04 Code 04: Master TPA Internal Fault

The power amplifier has detected an internal fault.

05 Code 05: Battery Sense

Out-of-Range/Master TPA

The TPA monitors battery voltage at B+Key. If voltage does not match configured voltage or is below set threshold, the code is displayed. The TPA also monitors the voltage on its internal capacitors. If voltage goes above 63VDC, the code is displayed.

06 Code 06: Short in Master TPA

When the Key switch is turned ON, the TPA momentarily powers each motor phase and monitors current. If current is seen when it should not be, this code is displayed.

07 Code 07: Open in Master TPA

When the Key switch is turned ON, the TPA monitors each motor phase for current draw. If current is not seen when it should be, this code is displayed.

Notes/Corrective Action

Check voltage to TPA. If OK, replace the TPA. Check communication wires between all modules for continuity and shorts to frame.

If code does not clear by cycling key, replace the TPA. If code clears, the adjustable parameters have been reset to default values and require resetting to customer’s requirements via FlashWare.

Check voltage to TPA. If OK, replace the TPA.

Check motor cables for continuity. Check motor cable connections for correct torque. Compare current from all 3 phases. If one phase is significantly higher or lower than the other two, replace the motor. If OK, replace the TPA.

Verify battery voltage. If wrong voltage, set correct voltage via FlashWare (and relearn pots) or install correct voltage battery.

If battery is correct but voltage is >63VDC, replace battery. Test power cables to the motor for shorts to frame and other cables.

Test the motor for shorts to frame. Resistance must be >1Meg ohm. If OK, replace the TPA.

Measure voltage and resistance across coil. Check cables to the motor and TPA for continuity and correct torque. Swap the connections from the TPA to the other traction motor using appropriately sized jumper cables and turn the Key switch ON. If code changes, replace the motor. If the code is still displayed, replace the TPA.

Check voltage to the TPA. Check cables to the motor and TPA for continuity and correct torque. Swap the connections from the PPA and pump motor with the TPA and traction motor using appropriately sized jumper cables and turn the Key switch ON. If code changes, replace the motor. If the code is still displayed, replace the TPA.

Publication 1160093, Issued: 20 May 2013 6-9

Section 6.Messages and Codes

Fault Codes

Model 4700 Maintenance Manual

Refer to the “Pinout Matrix” located in Theory of Operation section for all voltage and resistance values and component interconnection.

Code Description

08 Code 08: Traction Contactor Open When Commanded Closed

Correct voltage is not seen by the TPA at +V when CT3 is commanded closed.

09 Code 09: Master TPA Internal Fault

Failure of the current sensor.

10 Code 10: Master TPA Precharge Failure

When CT3 is closed, the TPA attempts to charge the internal capacitors. If the capacitors are not charged to B+ in a certain amount of time, this code is displayed.

11 Code 11: Master TPA Overtemperature

Internal temperature on the Master TPA is >167°F (75°C). Performance is reduced to 212 °F (100°C); travel is shut down above 212°F (100°C).

12 Code 12: Right Traction Motor Temperature Out-of-Range

Right traction motor overtemperature, above 266°F (130°C), or temperature switch is bad.

13 Code 13: Right Traction Motor Encoder Error

Incorrect or no input seen by the Master TPA from the right traction motor encoder.

14 Code 14: Master TPA Temperature Sensor Out-of Range

Temperature sensor has exceeded values expected.

Notes/Corrective Action

Inspect the contactor for physical binding and welded tips. Check fuse for the TPA (FT). Measure voltage and resistance across coil. Check cables from battery to TPA for continuity and correct torque. If OK, replace the TPA.

Check power cables at the motor and TPA for continuity and correct torque. Replace the TPA.

Check for B– at the TPA power input.

Check for B+ from CT3 to the B+ connection on the TPA. If not present, check the fuse for the TPA (FT). Measure voltage and resistance across CT3 coil. If OK, replace the TPA.

6-10

Check fan for correct operation. Fan should operate within about one minute after turning key ON. If not, troubleshoot fan. Check/clean air filter. Allow TPA time to cool. If code clears, check cables to the motor and TPA for continuity and correct torque. Check for brake drag. If code does not clear, replace the TPA.

If motor temperature is <266°F (130°C), check wiring to switch.

If motor temperature is >266 °F (130°C), compare current across the 3 phases for excessive current draw per the Pinout Matrix. Check drive unit for binding. If OK, replace the TPA.

Test the +12V and GND inputs to both encoders and the output from channels A and B to the amp from both encoders. Check resistor between 12V and Gnd. If OK, check for shorts to frame. Check voltage to the TPA. If OK, replace the TPA.

Check fan for correct operation. Fan should operate within about one minute after turning Key switch ON. If not, troubleshoot fan. If OK, replace the TPA.

Publication 1160093, Issued: 20 May 2013