Refer to the “Pinout Matrix” beginning on page 8-13 for all voltage and resistance values and component interconnection.
Code Description Notes/Corrective Action
01
Code 01: Master TPA Internal Fault
The power amplifier has detected an internal fault.
Check voltage to TPA. Check communication wires between all modules for continuity and shorts to frame per the Pinout Matrix. If OK, the TPA may be bad. Swap the TPAs. If the code changes, replace the bad TPA.
02
Code 02: Master TPA Internal Fault
Fault in the area of memory in which the adjustment parameters are stored.
If code does not clear by cycling key, the TPA may be bad. Swap the TPAs. If the code changes, replace the bad TPA. If code clears, the adjustable parameters have been reset to default values and require resetting to customer’s requirements via FlashWare.
03
Code 03: Master TPA Internal FaultThe power amplifier has detected an internal fault.Check voltage to TPA. If OK, the TPA may be bad. Swap the TPAs. If the code changes, replace the bad TPA.
04
Code 04: Master TPA Internal Fault
Correct current draw by the motor is not seen by 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. Measure voltage and resistance across coil and contact tips per the Pinout Matrix. If OK, the TPA may be bad. Swap the TPAs. If the code changes, replace the bad TPA.
05
Code 05: Battery Sense Out-of-Range/Master TPA
The Master TPA monitors the battery voltage at +V Key. If voltage is below a set threshold, the code is displayed. The TPA also monitors the voltage on its internal capacitors. If voltage goes above a set threshold, the code is displayed. This most likely occurs during plugging.
Measure voltage into amplifier at +V Key. Check
configured battery voltage (36V or 48V) with FlashWare. If incorrect, set correct battery voltage in FlashWare (and re-Learn pots) or replace battery with correct battery. Measure battery voltage at the Master TPA +BATT connection during plugging. If the voltage exceeds 63V, replace the TPA. Test power cables to the motor for shorts to frame and other cables. Test the motor for shorts to frame. Resistance must be >1 Megohm. If OK, the TPA may be bad. Swap the TPAs. If the code changes, replace the bad TPA.
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.
Test power cables for shorts. Swap the connections from the Master TPA to the left 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, the TPA may be bad. Swap the TPAs. If the code changes, replace the bad TPA.
Codes
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.
Check cables to the motor and TPA for continuity and correct torque. Swap the connections from the master TPA and the Slave 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, the TPA may be bad. Swap the TPAs. If the code changes, replace the bad TPA.
08
Code 08: Traction Contactor Open When Commanded Closed
Correct voltage is not seen by the TPA at +BATT when CT3 is commanded closed.
Inspect the contactor for physical binding and welded tips. Check the fuse for the TPAs (FT1 and FT2). Measure voltage and resistance across coil. Check cables from the battery to the TPA for continuity and correct torque. If OK, the TPA may be bad. Swap the TPAs. If the code changes, replace the bad TPA.
09
Code 09: Master TPA Internal FaultFailure of the current sensor.Check power cables at the motor and TPA for continuity and correct torque. If OK, the TPA may be bad. Swap the TPAs. If the code changes, replace the bad TPA.
10
Code 10: Master TPA Precharge Failure
When the key switch is turned ON, 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.
Check for B– at the TPA power input. Check for B+ from JT1-1 (+V Key). If OK, the TPA may be bad. Swap the TPAs. If the code changes, replace the bad TPA.
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).
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, the TPA may be bad. Swap the TPAs. If the code changes, replace the bad TPA.
12
Code 12: Right Traction Motor Temperature Above 266°F
Right traction motor overtemperature, above 266°F (130°C), or temperature switch is bad.
If motor temperature is <266 °F (130°C), check wiring to temperature switch TS1 from VM. If motor temperature is >266°F (130°C), allow motor to cool and measure current draw on each phase of the motor. All three phases should be approx. equal. If not, replace the motor. Check for binding in the drive unit or dragging brakes. If OK, the TPA may be bad. Swap the TPAs. If the code changes, replace the bad TPA.
Refer to the “Pinout Matrix” beginning on page 8-13 for all voltage and resistance values and component interconnection.
Model 4450 Maintenance Manual
Section 6. Messages and Codes
Codes
13
Code 13: Right Traction Motor Encoder Error
Incorrect or no input seen by the Master TPA from the right traction motor encoder.
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, the TPA may be bad. Swap the TPAs. If the code changes, replace the bad TPA.
14
Code 14: Master TPA Temperature Sensor Out-of Range
Temperature sensor has exceeded values expected.
Check fan for correct operation. Fan should operate within about one minute after turning Key switch ON. If not, troubleshoot fan. If OK, the TPA may be bad. Swap the TPAs. If the code changes, replace the bad TPA.
15
Code 15: Amplifier Enable
No B– input seen by the TPA.
Check for B– at both TPAs Safety In and Safety Out circuits (JT1-11 and 19; JT2-11 and 19). If OK, the TPA may be bad. Swap the TPAs. If the code changes, replace the bad TPA.
16
Code 16: Master TPA Detected CAN-Bus Error
The Master TPA has not received a communication message from the VM, HCB, or PPA.
Test battery voltage under load. In FlashWare, observe the software version of each device in the Truck Setup screen. Check voltage to the device that is not showing a software version. Check communication wires between the devices not showing the software version for continuity and shorts to frame. If OK, replace the device not showing the software version.
17
Code 17: CAN-Bus Node Offline
Too much time between
communication from the VM, Slave TPA, HCB or PPA to the Master TPA has elapsed. This code can also be caused by an open in a cable from the amplifier to the traction motors.
Check the power cables to the traction motors.Check both traction motor encoders, temperature sensors for opens, shorts and shorts to frame. In FlashWare, observe the software version of each device in the Truck Setup screen. Check voltage to the device that is not showing a software version. Check communication wires between the devices not showing the software version for
continuity and shorts to frame. If OK, replace the device not showing the software version.
18
Code 18: Relay 1 Not Energized By TPA
The Master TPA commanded Relay 1 to energize with truck configured for a 48V battery. Did not receive correct feedback.
Check Relay 1 by disconnecting from circuit. Check output to Relay 1 from Master TPA. If OK, replace Relay 1. If not OK, the TPA may be bad. Swap the TPAs. If the code changes, replace the bad TPA.
Refer to the “Pinout Matrix” beginning on page 8-13 for all voltage and resistance values and component interconnection.
Codes
19
Code 19: Traction Contactor Driver Shorted
The Master TPA detected excessive current draw when the CT3 contactor was commanded closed.
Measure voltage and resistance across coil. Check JT2-4 (Config) wiring and connection. Check wires to coil for shorts to other wires and the frame. If OK, the TPA may be bad. Swap the TPAs. If the code changes, replace the bad TPA.