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

76 Code 76: Slave TPA Detected

CAN-Bus Error

The Slave TPA has not received a communication message from the VM, HCB, or PPA.

77 Code 77: Slave TPA CAN-Bus Node

Offline

Too much time between communication from the VM and PPA to the TPA has elapsed. This code can also be caused by an open in a cable from the amplifier to the traction motors.

79 Code 79: Traction Contactor Driver Shorted

The TPA did not see a voltage drop when the contactor was commanded closed.

7A Code 7A: Master KO Failure of Master Unit.

7C Code 7C: Slave TPA Internal Fault Slave TPA internal fault.

80 Code 80: Traction Contactor Coil Driver Error

Failure of the contactor driver.

81 Code 81: Directional Microswitch Closed

VM detected directional microswitches (SW9 or SW10; SW4 or SW5 on dual pedal trucks ) closed prior to power up. This code can also be caused by having travel enable switch (SW8) activated before seat switch (SW2) and/or optional battery gate switch (SW30) is activated.

Notes/Corrective Action

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

6-20

Verify battery voltage. If wrong voltage, set correct voltage via FlashWare (and re-Learn pots) or install correct voltage battery. Check power cable connections to the TPA and motors for continuity and correct torque. Check both traction motor encoders, temperature sensors, and connections. Check communication wires between VM, TPA, and PPA for continuity and shorts to frame. If OK, replace the TPA.

Check the CT3 contactor for physical binding and welded tips.

Measure voltage and resistance across coil. If OK, replace the TPA.

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

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

Measure voltage and resistance across coil.

If the directional switch is left in forward or reverse position when the operator leaves the seat, Code 81 is displayed after a brief time-out (approx. 30 seconds). If the code still appears after lever is returned to neutral, cycle the Key switch to clear. Test switches for correct operation. Check continuity of wires from switches to cards. Flash truck components with latest version of software and re-Learn pots. Replace the VM.

Publication 1160093, Issued: 20 May 2013

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

83 Code 83: Traction Pot Open Circuit

VM detected the voltage from the traction pot is below the allowable voltage range.

84 Code 84: Travel Enable Switch Failure

VM detected travel enable microswitch (SW8) failure.

85 Code 85: Warning Configuration Error

Software error.

86 Code 86: Traction Potentiometer Out-of-Range

Traction Pot is outside the learned voltage range. This code can also be displayed if there is no power to the TPA or if one of the power cables to the traction motor(s) is open.

87 Code 87: Seat/Battery Gate Interlock Switch Open

A function was activated while the seat or optional battery gate interlock switch was open.

89 Code 89: Parking Brake Switch Error

SW7 is closed when travel is detected.

8A Code 8A: VM Internal Fault

A fault was detected by the VM during power up.

Notes/Corrective Action

Test for correct voltage to and from the traction pot. If voltage is not correct, check continuity of the wires. If OK, replace the VM. If not OK, replace the pot.

Troubleshoot switch and wiring. Check for shorts to frame. Troubleshoot SW5 and SW10 switches and wiring. If OK, replace the VM. If not OK, repair/replace the switch/wiring.

Check configured battery voltage (36V or 48V) with FlashWare. If incorrect, set correct battery voltage in FlashWare or replace battery with correct voltage battery. Replace VM.

If code is displayed in conjunction with another code, troubleshoot per that code. Verify battery voltage. If wrong voltage, set correct voltage via FlashWare (and re-Learn pots) or install correct voltage battery. Check both traction motor encoders, temperature sensors, and connections. Check power to the TPA. Check the power cables to the traction motor(s). Check pot voltages. Check resistance of resistor in static strap standoff; should be 200 to 250k ohm. Verify configuration jumpers are in place on PPA. If OK, run Learn. If not OK, replace the pot.

Troubleshoot switches and wiring.

Troubleshoot switch and wiring.

Replace the VM.

Publication 1160093, Issued: 20 May 2013 6-21