"3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008
Page 4-27
WIRING Messages
The following are “wiring” HELP messages – problems have been detected which are likely due to
vehicle wiring issues:
FAULT: ENERGIZED VALVE - CHECK P5 WIRING! ------------------------------- Flash Code: 3/2
FAULT: VALVE FEEDBACK HIGH - CHECK VALVE WIRING! --------------------- Flash Code: 3/2
• There is a voltage on one or more valve outputs, when all outputs are off.
• Check each valve output to trace where the invalid supply is coming from.
FAULT: CAPBANK VOLTAGE TOO HIGH - CHECK LINE CONT! ----------------- Flash Code: 3/3
• The voltage on the B+ stud of the controller (connected to an internal voltage stabilization capacitor bank) is
too high when the line contactor is off. B+ stud voltage should be approximately 32 volts at idle.
• Check the line contactor tips are not welded, and check the power wiring for errors .
FAULT: ENERGIZED LINE CONTACTOR - CHECK P5 WIRING! ----------------- Flash Code: 3/4
• There is a voltage on the line contactor coil output, when it is off.
• Check wiring to the line contactor coil to trace where the invalid supply is coming from.
FAULT: MOTOR OVERLOAD! ------------------------------------------------------------- Flash Code: 3/5
• The power protection circuits in the controller have activated to protect from extreme overload.
• Check for short-circuit power wiring; check for a seized or shorted motor.
P600 TEMPERATURE Messages
• This section lists “temperature” HELP messages – problems have been detected which are likely due to
excessive dutycycling or poor heatsinking:
FAULT: BAD INTERNAL TEMPERATURE SENSOR! -------------------------------- Flash Code: 4/1
• The heatsink temperature is out of range; if the fault remains, the power controller may have to be replaced.
FUNCTIONS LOCKED - TOO HOT! ------------------------------------------------------ Flash Code: 4/2
• The heatsink temperature exceeds 75ºc, preventing all functions except lowering. Check for excessive motor
current draw; check for good heatsinking to vehicle chassis.
SUPPLY Messages
The following are “supply” HELP messages – problems have been detected which are likely due to
supply issues:
FAULT: BAD INTERNAL 5V! --------------------------------------------------------------- Flash Code: 4/2
• The internal “5V slave” supply is out of range; if the fault remains, the controller may have to be replaced.
FAULT: BAD INTERNAL SLAVE! --------------------------------------------------------- Flash Code: 4/2
• The internal “slave” is not operating correctly; if the fault remains, the controller may have to be replaced.
FAULT: BAD INTERNAL 12V! ------------------------------------------------------------- Flash Code: 4/3
• The internal “12V” supply is out of range;
• 12V Supply is generated by the Motor control module and supplied to the GP400. Check for wiring errors
between the two modules. If the fault remains, the Motor Controller may have to be replaced.
FAULT: BATTERY VOLTAGE TOO LOW! ------------------------------------------------ Flash Code: 4/4
• The battery supply is too low – the batteries must be re-charged.
FAULT: BATTERY VOLTAGE TOO HIGH! ----------------------------------------------- Flash Code: 4/4
• The battery supply is too high – check that the correct battery and charger are installed.
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