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Vehicle Test Instructions for 
OHV 17KG551 Control Group
Document No. GEK-91843, Rev.B
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
ii Wabtec Proprietary and Confidential Information
GE CONFIDENTIAL TECHNICAL INFORMATION
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vail.
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Revision History
Rev Date By Description
NEW Apr-2018 SAM Initial release of publication.
A Jun-2018 SAM Changes to Section 5.8 Blower Test And Axle Box Pressure Switch. Changes to 
Table 8, Table 9, and Table 10.
B Feb-2020 Updated Table 6, “Power Supply Checks,” to add physical checks as per Main 
Workflow: 200257586 and Writer’s Workflow: 200277121.
BP
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
TABLE OF CONTENTS
Section Page
1. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2. RELATED PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3. SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4. CAPACITOR DISCHARGE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. TOOLS, TEST EQUIPMENT, AND HANDLING ELECTRONIC COMPONENTS . . . . . . . . . . 17
2.1. TOOLS AND TEST EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2. HANDLING ELECTRONIC PANEL PRINTED CIRCUIT CARDS . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3. PRE-POWER UP CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.1. WIRING CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2. CONFIGURATION MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3. GENERAL CLEAN-UP AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4. TRUCK INITIAL CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1. LOW VOLTAGE POWER SUPPLY CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2. VERIFY GE DRIVE SYSTEM SOFTWARE REVISIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3. SETUP AND CONFIG DSC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.4. CIRCUIT CONTINUITY, RESISTANCE CHECKS, AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . 27
4.5. MEGGER TEST FOR GROUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5. ENGINE RUNNING CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.1. INITIAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2. BATTERY BOOST CIRCUIT VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.3. VI TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.4. CAPACITANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.5. DIRECTIONAL CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.6. LOSS OF J1939 COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.7. ENGINE WARNING (RED LIGHT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.8. BLOWER TEST AND AXLE BOX PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.9. SELF LOAD (LOADBOX) TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.10. POWER MODULE VIBRATION MEASUREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6. GLOSSARY OF TERMS, ACRONYMS, AND ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . 48
A. PRE-POWER UP CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
B. TRUCK INITIAL CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
C. ENGINE RUNNING TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
D. KEY SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
E. FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . 73
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LIST OF FIGURES
Figure Page
1
2
Primary And Secondary DC Link Discharge Paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 
Switch Panel With Control Power Switch (CPS) And Generator Field Cut
Out (GFCO) Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Capacitor Charged Light Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Testing Meter Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 DC Meter On Primary DC Link Capacitor Positive (+) And Negative (-) Terminal Posts . 11
6 DC Meter On Secondary DC Link Capacitor Positive (+) And Negative (-) Terminal Posts 12
7 Discharge Stick Center Tap Ground Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8 Discharge Stick Tip Ground Resistance Measurement Locations . . . . . . . . . . . . . . . . . . . . 14
9 Jumper All Terminals On Isolated Primary DC Link Capacitor . . . . . . . . . . . . . . . . . . . . . . . 16
10 Jumper All Terminals On Isolated Secondary DC Link Capacitor. . . . . . . . . . . . . . . . . . . . . 16
11 Thumb Screw Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
12 Card Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
13 Card Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
14 Card Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
15 Torque Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
16 VAM1-4 Output Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
17 VAM4 High Voltage Input Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
18 RTN Bus Output Terminal And GND1 Ground Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
19 CNB Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
20 CCLR1 And 2 CN1 Output Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
21 DC+ And DC- Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
22 DCP Bus And DCN Bus Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
23 GND9 Ground Block And CCLR3 And CCLR4 Output Connectors . . . . . . . . . . . . . . . . . . . . 35
24 CI1, CI2, GI1, And GI2 Connectors From The SLVB Bus Bar . . . . . . . . . . . . . . . . . . . . . . . . . . 35
25 SDCN Bus And SDCP Bus Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
26 Vibration Probe Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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1. GENERAL INFORMATION
1.1. INTRODUCTION
This document describes the recommended truck start-up and checkout procedures at an Original Equipment Man-
ufacturer (OEM) facility or mine site. Repeating the factory checkout at the mine site is required to verify the system
properly functions after being torn down to ship. The information applies to truck models with AC drive systems uti-
lizing the 17KG551 control group with Invertex IIe control panel.
The document is written sequentially so that each step depends on previous steps being successfully completed
prior to going on to the next step. The overall process of commissioning and testing a truck is Truck OEM responsibil-
ity. This document is a subset of that procedure. Truck OEM documentation is required to successfully complete
this procedure which includes but is not limited to: wiring diagrams, layout drawings, checkout procedures, safety
procedures, and equipment installation instructions. 
This document is written for a user that is a trained electrical worker that can read schematics, who is trained in
safety procedures including lock out tag out, and trained on operating the test equipment described in this manual.
The user is expected to have knowledge on the functions that are called out in this manual. Functions are called out
where appropriate using FUNCTIONS style text. That link will send you to an Appendix with basic information about
the function and where to access the function’s properties. To further aid the user on user interface functions refer-
ence GEK-91842, HUMAN MACHINE INTERFACE (HMI) MANUAL that provides additional information on where to
locate the functional controls to complete the necessary tasks.
Sign off sheets are provided in the appendix for documenting the successful completion of each step of the proce-
dure. As a minimum the sign off sheets should be completed with who and when the items were completed and
should be available to provide technical support when resolving product or warranty issues, as required.
For terms, acronyms, and abbreviations used in this publication, refer to section 6., GLOSSARY OF TERMS, ACRO-
NYMS, AND ABBREVIATIONS.
1.2. RELATED PUBLICATIONS
When using related publications, use the highest letter revision publication for current information. Check with the
GE Representative or GE web site for the latest letter revision of the publication.
Table 1. Related Publications
Publication Name Publication Number
GE OHV AC Control System Events And Historical Counters, And Profiles GEK-91756
OHV Human Machine Interface (HMI) GEK-91842
Revisions are indicated by change bars.
Wabtec Proprietary and Confidential Information 1
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
1.3. SAFETY INFORMATION 
All applicable local regulations including any OEM test facility, Mine, Government, and Industry rules for working with
high voltage must be followed. Required personal protective equipment, including but not limited to safety shoes,
high voltage gloves, and safety glasses must be worn. 
Safety Cautions and Warnings appear throughout the instructions. 
Indicates the potential for personal injury.
Indicates the potential for equipment damage.
The following is a summary of the WARNINGS and CAUTIONS that are found in this publication. Observe this safety
information carefully to avoid personal injury or equipment damage.
NOTE: Read these Warnings before proceeding to other sections of this publication.
Hazardous voltages are present in this equipment. Ensure the Control Power Switch
(CPS) is in the OFF position and the Generator Field Contactor (GFCO) switch is in the
CUTOUT position before attempting any work on control components. Check that
Capacitor Charge Lights (CCLs) are not illuminated. Use a VOM to VERIFY that no volt-
age is present before touching any terminal. Failure to observe these precautions may
result in injury, death, or equipment damage.Hazardous voltages may be present in this equipment even if the engine and Capaci-
tor Charge Lights are off. Use measurement and protective equipment rated for 2000
VDC minimum to verify that no voltage is present before touching any terminal. Verify
functionality of the measurement equipment using site-approved procedures both
before and after performing control group measurements. Failure to observe these
precautions may result in death or serious personal injury. 
Hazardous voltages are present in this equipment. Use caution and avoid touching
any energized equipment when the door to the Low Voltage area is open. Failure to do
so may result in death or serious personal injury.
Voltages in excess of 1500 VDC may be present. Any measurement and/or protective
equipment used must be rated at 2000 VDC minimum. Verify the measurement equip-
ment functions properly using site-approved procedures both before and after per-
forming control group measurements. Failure to observe these precautions may result
in death or serious personal injury.
Electric shock can cause serious or fatal injury. To avoid such injury, personnel should
take and observe proper precautions when making system adjustments or performing
system or component electrical tests.
WARNING
CAUTION
WARNING
WARNING
WARNING
WARNING
WARNING
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GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Personnel must not touch and remain clear of all components, cables, or terminals
during and after megger tests due to electrical hazard. Failure to observe these pre-
cautions may result in death or serious personal injury.
The DC link will hold a capacitor charge after megger testing the main power circuit.
Allow sufficient time for it to discharge. Failure to observe these precautions may
result in death or serious personal injury.
Ensure the correct Configuration software is loaded into the truck CPUs. Loading the
wrong Configuration software may result in improper truck operation which may
endanger personnel and damage the truck. If the correct Configuration file require-
ments are uncertain, contact GE OHV Representatives.
Ensure that all Mine, OEM, and GE safety procedures are followed during truck soft-
ware installation. Ensure the truck is parked in a safe location with the Park Brake
applied and GF Cutout switch is in the CUTOUT position (down), which places propul-
sion system in REST mode. Failure to observe these precautions may result in death or
serious personal injury, as well as equipment damage and inadvertent truck move-
ment.
Before attempting to adjust switch, system must be de-energized before opening
cover to adjust switch.
Follow all local safety procedures, mine procedures, verify personnel are clear of the
truck, and truck components are prepared for engine start and Self Load (Loadbox).
Failure to observe these precautions may result in death or serious personal injury,
and truck or drive system component damage.
This procedure MUST be performed exactly as written. Failure to do so may result in
personal 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.
The truck should not move during engine start. To protect personnel and equipment
from a malfunction during initial start up, ensure all personnel and equipment are
clear in front of and behind the truck. Failure to observe these precautions may result
in personal injury or death.
Only trained personnel should perform ground detection verification tests. Attempting
these tests without proper training may result in injury or death.
A successful megger test must be performed on the power circuits before attempting a
ground circuit test. If a ground exists when the test ground is introduced, the intro-
duced ground wire may melt. Always perform the megger test to avoid introducing
another ground in the power circuit. Failure to observe these precautions may result
in death or serious personal injury.
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
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GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Use a megger with a discharge setting. Failure to do so may result in death or serious
personal injury.
Only trained personnel should perform control tests. Attempting to perform control
tests without training may result in injury or death.
DC Voltage must be measured every time the cabinet doors are opened.
Battery input to FH46 Power Supply will have battery voltage applied to it if the key
switch is OFF, the battery disconnect is closed, and the control power switch is OFF.
The INPUT LED will remain lit and all other LEDs will be off. Failure to observe these
precautions may result in serious personal injury or death.
The FH46 module has internal capacitors. Opening the FH46 module may result in
serious personal injury or death.
If cards must be removed from a panel, power to the panel must be turned OFF before
removing or inserting cards into the panel. Failure to do so may result in damage to
cards and other electronic components.
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 precau-
tions could damage electronic components mounted on them. Also, when transport-
ing or storing these cards, industry recommended special static electricity proof
containers must be used.
In REST mode, all control components still have control power from the power supply
and are still functioning. Prior to attempting to remove or unplug control components,
remove all control power. Failure to do so may result in damaged control components.
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 to energize.
Do not use bell ringer wiring tester; use an ohmmeter or light continuity tester.
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.
Failure to verify CCL1, CCL2, CCL3, and CCL4 are off prior to starting inverter download
may cause equipment damage.
WARNING
WARNING
WARNING
WARNING
WARNING
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
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GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Do not cycle power once application of software starts to download as equipment
damage may result.
A successful megger test must be performed on the power circuits before attempting a
ground circuit test. If a ground exists when the test ground is introduced, the intro-
duced ground wire may melt. Always perform the megger test to avoid introducing
another ground in the power circuit. Failure to do so may result in equipment damage.
Do not put shorting wire on terminal boards.
Prior to Self Load (Loadbox) all prior checks must be completed.
1.4. CAPACITOR DISCHARGE PROCEDURE
1.4.1. Purpose 
The purpose of this section is to outline the discharge procedure for the primary and secondary DC Link Capacitors
in case of failure of the built-in discharge circuits in GE IGBT control groups. This procedure affects all GE Invertex IIe
AC Drive Systems using 17KG551 control cabinets.
1.4.2. Primary And Secondary DC Link
The primary DC link is supplied by the traction alternator through the main rectifier. It supplies power to the traction
inverters. Refer to Figure 1. When energized, the nominal voltage range is 600Vdc to 1500Vdc.
NOTE: The primary DC link is charged to approximately 3Vdc when deenergized and the control power is on due
to the interaction of the primary H-bridge gate driver modules.
The secondaryDC link is supplied through the primary H-bridge, secondary link transformer and secondary H-
bridge. It supplies power to the cooling blower inverters. Refer to Figure 1. When energized, the nominal voltage
range is 300Vdc to 800Vdc.
NOTE: The secondary DC link is charged to approximately 0.3Vdc when deenergized and the control power is on
due to the interaction of the cooling blower inverter gate drivers.
The normal (fast) discharge sequence is utilized every time the system is shut down and typically discharges both DC
links within 10 seconds. The normal discharge sequence is listed below (Refer to Figure 1).
1. Turn off blower and traction inverters.
2. Discharge SLFC1-7 through SB / SLT / PB1 / PB2 to primary DC link.
3. Discharge LFC1-6 through RG1-4 Circuits / CM1-4.
The primary DC link back-up (slow) discharge path is in parallel through FDR and GRR (Refer to Figure 1). This path
discharges the link within 5 minutes.
CAUTION
CAUTION
CAUTION
CAUTION
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GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
The secondary DC link back-up (slow) discharge path is in parallel through SGRR1/2 and SGRR3/4 (Refer to Figure 1).
This path discharges the link within 5 minutes.
1.4.3. Materials Required
• As needed – ½” UNC bolt x 1 ½” long (minimum), for discharge stick ground connection.
• As needed – quantity 2 M6 x 12mm (minimum length) generic screw for secondary DC link capacitor terminal
shorting for each capacitor removed from the GE control group.
• As needed – foot long minimum piece of small gage bare wire for both primary and secondary DC link capacitor
shorting for each capacitor removed from the GE control group
1.4.4. Special Tools And Processes Required
• Personal Protective Equipment (PPE) for working with 2000 VDC 
• 2000 VDC meter / capacitor discharge kit (Bierer RCDCKOM or equivalent). For further information, refer to
www.bierermeters.com.
• Multimeter – minimum CAT III 1000V
1.4.5. Manual DC Link Capacitor Discharge Procedure
1.4.5.1. Preparation
Follow any and all local and site-specific procedures and requirements for working on OHV equipment. Verify that:
1. The diesel engine is shut down, the Park Brake is set and the truck is properly chocked.
2. The generator field is cutout via the GFCO switch in the Low Voltage Area of the control cabinet. Refer to Figure
2.
3. Apply control power for a minimum of 30 seconds, then turn the control power OFF using the Control Power
Switch on the switch panel (Figure 2).
NOTE: With control power ON, the normal discharge sequence is activated if the system determines that either
the primary or secondary link voltage is over 10Vdc. Refer to section 1.4.2., PRIMARY AND SECONDARY DC LINK
and Figure 1 for normal discharge sequence. 
6 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Figure 1. Primary And Secondary DC Link Discharge Paths
DC
P 
Bu
s
( -
)
( +
 )
( -
)
( +
 )
( -
)
( +
 )
( -
)
( +
 )
( -
)
( +
 )
( -
)
( +
 )
( -
)
( +
 )
( -
)
( +
 )
( -
)
( +
 )
DC
HB
Bu
s B
ar
( -
)
( +
 )
From RD
(Primary DC Link Source)
DC
N
 B
us
CM1
CM2 CM4
CM3
PB1
PB2
Tr
ac
�o
n 
In
ve
rt
er
 H
ar
dw
ar
e
N
ot
 S
ho
w
n
LF
C1
LF
C2
LF
C3
LF
C4
LF
C5
LF
C6
SD
CP
( +
 )
Bu
s
SD
CN ( -
)
Bu
s
Co
ol
in
g
Bl
ow
er
In
ve
rt
er
Ha
rd
w
ar
e
N
ot
Sh
ow
n
SB
SLT
( -
)
( +
 )
( -
)
( +
 )
( -
)
( +
 )
( -
)
( +
 )
( -
)
( +
 )
( -
)
( +
 )
( -
)
( +
 )
CV
B
FDR
GR
R
RG1 Circuit
RG3 Circuit
RG2 Circuit
RG4 Circuit
SLVB Bus Bar
SLFC1 SLFC2 SLFC3 SLFC4 SLFC5 SLFC6 SLFC7
GRD
( +
 )
A B
Co
nt
ro
l G
ro
up
N
ot
e 
1:
 L
FC
1 
–
LF
C6
 
ar
e 
pr
im
ar
y 
DC
 li
nk
 
(t
ra
c�
on
) p
ow
er
 
ca
pa
ci
to
rs
N
ot
e 
3:
 S
LT
 is
 lo
ca
te
d 
at
 th
e 
tr
uc
k 
de
ck
 le
ve
l 
be
hi
nd
 th
e 
Co
nt
ro
l 
G
ro
up
Retarder
SG
RR
1/
2
SG
RR
3/
4
N
ot
e 
2:
 S
LF
C1
 –
SL
FC
6 
ar
e 
se
co
nd
ar
y 
DC
 li
nk
 
(c
oo
lin
g 
bl
ow
er
) 
po
w
er
 ca
pa
ci
to
rs
N
or
m
al
 (F
as
t)
 D
is
ch
ar
ge
 S
eq
ue
nc
e:
 1
. T
ur
n 
off
 b
lo
w
er
 a
nd
 tr
ac
�o
n 
in
ve
rt
er
s.
 2
. D
isc
ha
rg
e 
SL
FC
1-
7 
th
ro
ug
h 
SB
 / 
SL
T 
/ P
B1
 / 
PB
2 
to
 p
rim
ar
y 
DC
 li
nk
. 
3.
 D
isc
ha
rg
e 
LF
C1
-6
 th
ro
ug
h 
RG
1-
4 
Ci
rc
ui
ts
 / 
CM
1-
4.
Pr
im
ar
y 
DC
 L
in
k 
(T
ra
c�
on
) B
ac
k-
up
 (S
lo
w
) D
is
ch
ar
ge
 
Pa
th
:I
n 
pa
ra
lle
l t
hr
ou
gh
 F
DR
 a
nd
 G
RR
.
Se
co
nd
ar
y 
DC
 L
in
k 
(C
oo
lin
g 
Bl
ow
er
) B
ac
k-
up
 (S
lo
w
) 
Di
sc
ha
rg
e 
Pa
th
:I
n 
pa
ra
lle
l t
hr
ou
gh
 S
G
RR
1/
2 
an
d 
SG
RR
3/
4.
( +
 )( -
)
Bu
s b
ar
( +
 )
( -
)
E-63834
Wabtec Proprietary and Confidential Information 7
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
1.4.5.2. Capacitor Charge Lights
The primary DC link has two separate capacitor charge lights (CCL1, CCL2). The secondary DC link also has two sep-
arate capacitor charge lights (CCL3, CCL4). All lights can be viewed from the front of the control group as shown in
Figure 3. The lights will stay illuminated as long as the voltage on the respective DC link is greater than 50 VDC.
Hazardous voltages may be present in this equipment even if the engine and Capaci-
tor Charge Lights are off. Use measurement and protective equipment rated for 2000
VDC minimum to verify that no voltage is present before touching any terminal. Verify
functionality of the measurement equipment using site-approved procedures both
before and after performing control group measurements. Failure to observe these
precautions may result in death or serious personal injury.
Figure 2. Switch Panel With Control Power Switch (CPS) And Generator Field Cut Out (GFCO) Switches
WARNING
E-55902
8 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Figure 3. Capacitor Charged Light Locations
E-63835
SW
IT
CH
 P
AN
EL
(R
EF
 F
IG
U
RE
 2
)
LO
W
 V
O
LT
AG
E
CO
M
PA
RT
M
EN
T
PR
IM
AR
Y 
D
C 
LI
N
K
CH
AR
G
ED
 L
IG
H
TS
CO
O
LI
N
G
 B
LO
W
ER
CO
N
N
EC
TI
O
N
CO
M
PA
RT
M
EN
T
SL
VB
BU
S 
BA
R
(R
EF
 F
IG
U
RE
 1
)
SL
FC
CA
PA
CI
TO
R
CO
N
N
EC
TI
O
N
S
(R
EF
 F
IG
U
RE
 1
)
SE
CO
N
D
AR
Y 
D
C 
LI
N
K
CH
AR
G
ED
 L
IG
H
TS
CC
L3
CC
L4
D
CH
B 
BU
S 
BA
R
(R
EF
 F
IG
U
RE
 1
)
LF
C 
CA
PA
CI
TO
R
CO
N
N
EC
TI
O
N
S
(R
EF
 F
IG
U
RE
 1
)
CC
L1
CC
L2
Wabtec Proprietary and Confidential Information 9
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
1.4.5.3. Failure Of Capacitor Discharge System
If the Capacitor Charge Lights remain illuminated when the engine is shut down, a failure of the normal capacitor
discharge system has likely occurred. The back-up discharge paths should then discharge the respective DC link
capacitors within 5 minutes of the engine shutting down. If after 5 minutes the Capacitor Charge Lights are still illu-
minated, it must be assumed that both the normal and back-up discharge functionality of the system have been
compromised.
1.4.5.4. Measure DC Voltage On Capacitors
DC Voltage on capacitors must be measured every time the cabinet doors are opened
to the compartments indicated in Figure 3.
A convenient place to test meter functionality is at the terminals of the power conditioner (PC) in the low voltage
compartment – Refer to Figure 4. These terminals will have main battery voltage present as long as the main battery
switch is closed.
Figure 4. Testing Meter Functionality
1.4.5.4.1.Primary DC Link.
Ensure that the control power is turned off using the Control Power Switch on the switch panel (Figure 2). The main
battery switch can remain on (and allows for easy check of meter functionality at PC – Refer to Figure 4).
NOTE: PrimaryDC link voltage measurements need to be done with the control power off as the primary DC link
is charged to approximately 3Vdc when de-energized and the control power is on due to the interaction of the
primary H-bridge gate driver modules.
WARNING
E-63836
TEST METER
FUNCTIONALITY
ON PC TERMINALS
WITH MAIN 
BATTERY SWITCH
CLOSED
LOW VOLTAGE
COMPARTMENT
PC
10 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Refer to Figure 3 LFC capacitor connections on DCHB bus bar. Access this compartment to measure voltage on pri-
mary DC link capacitors. The top connections / terminals on the DCHB bus bar are positive (+) – Refer to Figure 1.
With a suitable high voltage meter rated for at least 2000 VDC, such as a Bierer RCDCKOM or equivalent, and with
suitable protective equipment, measure the voltage across each of the DC link capacitors. Place one meter lead on
the positive (+) capacitor terminal, and the other meter lead on the diagonally located negative (-) capacitor terminal,
and observe the voltage. Refer to Figure 5. If the voltage is less than 1.0 V, the capacitor is sufficiently discharged.
Repeat on all DC Link capacitors. If the voltage of any capacitor is above 1.0 V, manually discharge the capacitor as
described in section 1.4.5.5., MANUAL DISCHARGE OF CAPACITORS.
Figure 5. DC Meter On Primary DC Link Capacitor Positive (+) And Negative (-) Terminal Posts
1.4.5.4.2.Secondary DC Link
Ensure that the control power is turned off using the Control Power Switch on the switch panel (Figure 2). The main
battery switch can remain on (and allows for easy check of meter functionality at PC – Refer to Figure 4).
NOTE: Secondary DC link voltage measurements need to be done with the control power off as the secondary DC
link is charged to approximately 0.2Vdc when de-energized and the control power is on due to the interaction of
the Cooling Blower Inverter gate driver modules.
Refer to Figure 3 SLFC capacitor connections on SLVB bus bar. Access this compartment to measure voltage on sec-
ondary DC link capacitors. The top connections / terminals on the capacitors are positive (+). Refer to Figure 1.
With a suitable voltage meter rated for at least 1000 VDC, such as a CAT III 1000V multimeter or a Bierer RCDCKOM
or equivalent, and with suitable protective equipment, measure the voltage across each of the DC link capacitors.
Place one meter lead on the positive (+) capacitor terminal, and the other meter lead on the negative (-) capacitor
terminal, and observe the voltage. Refer to Figure 6 (shows use of Bierer RCDCKOM meter).
E-56036
Wabtec Proprietary and Confidential Information 11
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
NOTE: The RCDCKOM meter and discharge stick tips will not contact the capacitor terminals if centered over the
terminals. To provide contact, the tips must be offset as shown in Figure 6. 
If the voltage is less than 1.0 V, the capacitor is sufficiently discharged. Repeat on all DC Link capacitors. If the volt-
age of any capacitor is above 1.0 V, manually discharge the capacitor as described in section 1.4.5.5., MANUAL DIS-
CHARGE OF CAPACITORS.
Figure 6. DC Meter On Secondary DC Link Capacitor Positive (+) And Negative (-) Terminal Posts
1.4.5.5. Manual Discharge of Capacitors
If the voltage is greater than 1V on any of the capacitors, the capacitor must be manually discharged. With a suit-
able capacitor discharge device, such as the discharge sticks provided in the Bierer RCDCKOM kit, discharge the
capacitors where needed per the following instructions.
1.4.5.5.1.Discharge Stick Ground Connection
1. Proper discharge sticks have a center tapped connection point that needs to be solidly connected to a ground
point on the control cabinet prior to actively using them to discharge capacitors. Refer to Figure 7 for the loca-
tion of the center tap connection on the Bierer RCDCKOM discharge sticks.
E-63837
RCDCKOM KIT
TIPS MUST BE OFFSET
TO PROVIDE CONTACT 
WITH CAPACITOR
TERMINALS
12 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Figure 7. Discharge Stick Center Tap Ground Connection
2. Pick a convenient ground point to clip the ground connection to.
a. Primary and Secondary DC Link – with the Inverter compartment door(s) open, thread a ½” UNC bolt with a
minimum length of 1 ½” into the bottom door latch bolt hole and use this as the ground connection point.
Refer to Figure 7.
3. Once the ground connection is made, check the resistance to ground of each individual discharge stick tip but to
a different convenient ground point.
a. Primary and Secondary DC Link – with the Inverter compartment door(s) open, measure each discharge
stick tip resistance to the middle door latch bolt hole. Refer to Figure 8. Ensure that the resistance measured
is in the range of 80 ohms minimum to 250 ohms maximum per discharge stick.
NOTE: Each discharge stick included in the Bierer RCDCKOM kit has a nominal resistance of 180 ohms with an
expected tolerance of +/- 20%. Using worst case upper tolerance yields 216 ohms.
E-63838
PRIMARY DC LINK
CAPACITOR DISCHARGE
CONNECTION POINT
RCDCKOM
DISCHARGE STICK
CENTER TAP
GROUND
CONNECTION
SECONDARY DC LINK
CAPACITOR DISCHARGE
CONNECTION POINT
Wabtec Proprietary and Confidential Information 13
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Figure 8. Discharge Stick Tip Ground Resistance Measurement Locations
1.4.5.5.2.Discharge Primary DC Link Capacitors
1. Ensure that the discharge stick ground is connected properly per section 1.4.5.5.1., DISCHARGE STICK GROUND
CONNECTION.
2. Place one grounding stick on one of the positive (+) capacitor terminals and the other on the diagonally located
negative (-) terminal. Refer to Figure 1 for capacitor terminal polarity and Figure 5 for an example of discharge
stick tip placement (same as meter tip placement). Attempt to minimize the time between applications of the
positive stick and the negative stick so that the current flow will be positive to negative rather than either to
ground. Leave sticks in place until capacitors are discharged. For maximum 250 ohms per discharge stick, the
discharge times from 2000 volts are:
• 10 seconds maximum for one capacitor
• 60 seconds maximum for six (all) capacitors
Voltages in excess of 1500 VDC may be present. Any measurement and/or protective
equipment used must be rated at 2000 VDC minimum. Verify the measurement equip-
ment functions properly using site-approved procedures both before and after per-
forming control group measurements. Failure to observe these precautions may result
in death or serious personal injury.
3. Re-measure voltage on all capacitors as described in section 1.4.5.4., MEASURE DC VOLTAGE ON CAPACITORS.
Discharge any capacitors that show voltage. 
4. If all capacitors read discharged, verify that the meter is functioning correctly using site-approved procedures. If
so, proceed to the next section. 
E-63839
TRACTION INVERTER
COMPARTMENT RIGHT
HAND DOOR
MEASURE RESISTANCE
BETWEEN DISCHARGE
STICK TIP AND THE
INSIDE OF THIS BOLT HOLE
PRIOR TO DISCHARGING
PRIMARY DC LINK
CAPACITORS
MEASURE RESISTANCE
BETWEEN EACH
DISCHARGE STICK TIP
AND THE INSIDE OF THIS
BOLT HOLE PRIOR TO
DISCHARGING 
SECONDARY DC
LINK CAPACITORS
WARNING
14 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
1.4.5.5.3.Discharge Secondary DC Link Capacitors
1. Ensure that the discharge stick ground is connected properly per section 1.4.5.5.1., DISCHARGE STICK GROUND
CONNECTION.
2. Place one grounding stick on the positive (+) capacitor terminal and the other on the negative (-) terminal. Refer
to Figure 1 for capacitor terminal polarity and Figure 6 for an example of discharge stick tip placement (same as
meter tip placement). Attempt to minimize the time between applications of the positivestick and the negative
stick so that the current flow will be positive to negative rather than either to ground. Leave sticks in place until
capacitors are discharged. For maximum 250 ohms per discharge stick, the discharge times from 1000 volts
are:
a. 10 seconds maximum for one capacitor
b. 45 seconds maximum for seven (all) capacitors
NOTE: The RCDCKOM meter and discharge stick tips will not contact the capacitor terminals if centered over the
terminals. To provide contact, the tips must be offset as shown in Figure 6. 
Voltages in excess of 900 VDC may be present. Any measurement and/or protective
equipment used must be rated at 1000 VDC minimum. Verify the measurement equip-
ment functions properly using site-approved procedures both before and after per-
forming control group measurements. Failure to observe these precautions may result
in death or serious personal injury.
3. Re-measure voltage on all capacitors as described in section 1.4.5.4., MEASURE DC VOLTAGE ON CAPACITORS.
Discharge any capacitors that show voltage.
4. If all capacitors read discharged, verify that the meter is functioning correctly using site-approved procedures. If
so, proceed to the next section.
1.4.5.6. Short Isolated Capacitor Terminals
Hazardous voltages may be present in this equipment even if the engine and Capaci-
tor Charge Lights are off. Use measurement and protective equipment rated for 2000
VDC minimum to verify that no voltage is present before touching any terminal. Verify
functionality of the measurement equipment using site-approved procedures both
before and after performing control group measurements. Failure to observe these
precautions may result in death or serious personal injury. 
Any capacitor that is isolated from the DC Link and confirmed discharged MUST have its terminals electrically
shorted together to prevent static charge buildup. Use small gage bare wire to jumper the terminals on the capaci-
tor.
NOTE: The Secondary DC Link Capacitors require a M6 x 12mm (minimum length) generic screw be installed into
each terminal to perform this task.
Refer to Figure 9 for Primary DC Link Capacitor and Figure 10 for Secondary DC Link Capacitor.
Proceed to troubleshoot and repair the control group to restore it to original functionality.
WARNING
WARNING
Wabtec Proprietary and Confidential Information 15
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Figure 9. Jumper All Terminals On Isolated Primary DC Link Capacitor
Figure 10. Jumper All Terminals On Isolated Secondary DC Link Capacitor
E-53240
E-63840
JUMPERED TERMINALS
16 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
2. TOOLS, TEST EQUIPMENT, AND HANDLING ELECTRONIC COMPONENTS
2.1. 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. Personal computer with wired ethernet port running Google Chrome. All drive system adjustments are made
with a browser connected to WebPTU.
2. Analog Multimeter and Digital Multimeter (IEC-1010-1 — CAT III/1000 V meter).
3. Megger™ (Trademark of James G. Biddle Co.) 0 to 1500 volt max. (0 to 2000 Megohms) @ 2 mA max.
4. Cable, 9 pin RS232 communications cable with 1 male end connector and 1 female end connector.
5. 0.25 in. thin wall socket.
6. Connector pin extraction and insertion tooling as shown in Table 2.
7. Fluke 89 IV or equivalent with capacitance measurement capability.
8. Personal Protective Equipment (PPE) for working with 2000 VDC.
9. 2000 VDC meter / capacitor discharge kit (Bierer RCDCKOM or equivalent). For further information, refer to
www.bierermeters.com.
10. Multimeter – minimum CAT III 1000V.
11. ESD bags
12. ESD personal grounding strap/device
13. Philips screwdriver
14. Torque drive with Philips tip
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.
Table 2. Pin Extraction and Insertion Tooling
Amp Part Number or Tool Name Connectors
Pin Extraction
PEI Genesis (ITT Cannon Distributor)
M81969/19-07
AN1S
AN25
EN2S
USB1S
PEI Genesis (Amphenol Distributor)
DRK83-20B
ETC2S
USC1S
Wabtec Proprietary and Confidential Information 17
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
2.2. HANDLING ELECTRONIC PANEL PRINTED CIRCUIT CARDS
It is not recommended to pull cards from the panel any more often 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 could cause a control system malfunction.
All applicable local facilities including any OEM test facility, Mine, Government, and
Industry rules for working with high voltage must be followed. Required personal
protective equipment, including but not limited to safety shoes, high voltage gloves,
and safety glasses must be worn.
If cards must be removed from a panel, power to the panel must be turned OFF before
removing or inserting cards into the panel. Failure to do so may result in damage to
cards and other electronic components.
Personnel handling electronic cards must wear a static wrist strap with a ground
connection. Electronic cards should be transported in static bags. Electronic cards
should be placed on a static mat before removing covers. Failure to utilize static
electricity protection when handling electronic cards may damage and fail the card.
Card Removal Procedure:
1. Verify power is off to the entire control cabinet.
2. Connect personal grounding strap to ground (use the cabinet or other chassis ground).
3. Card removal
a. Loosen the thumbscrew using a Phillips head screw driver (Figure 11). It is not advisable to use a power
driver or drill as the possibility of stripping out the screw head is greater. The screws will not come all the
way out; they just need to clear the lower weldment.
Pin Insertion
PEI Genesis (ITT Cannon Distributor)
M81969/17-03
AN1S
AN2S
EN2S
USB1S
PEI-Genesis (Amphenol Distributor)
DAK83-20B
ETC2S
USC1S
Table 2. Pin Extraction and Insertion Tooling (Continued)
Amp Part Number or Tool Name Connectors
WARNING
CAUTION
CAUTION
18 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Figure 11. Thumb Screw Removal
b. Grasp the card by the handle located (Figure 12) on the center of the faceplate and gently rock back and
forth (vertically) until the card disengages from the backplane.
c. Gently slide the card straight out (Figure 13) of the card guides and place into an ESD bag for return. Avoid
contact with components by handling card by the edges.
E-63848
Wabtec Proprietary and Confidential Information 19
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Figure 12. Card Handle
Figure 13. Card Removal
E-63849
E-63850
20 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Card Installation Procedure:
1. Check there are no bent pins or obstruction(s) in the 210 pin connector on the backplane. Also review the card
210 edge connector for obstruction(s) in the mating sockets. 
2. Verify the orientation of the card. This can be accomplished by examining the 210 pin edge connector and the
plug on the backplane. There are two wings on the connector that will only line up in the correct orientation. 
3. Using the handle on the card, gently slide card into card guides but do not fully insert into the backplane. Make
sure the card remains vertical and in the card guides (minimal vertical or horizontal tilting of the card). 
4. Carefully apply force to the card edges (Figure 14) using and seat the card with minimal force, do not use the
handleto insert card.
5. Tighten the two card screws (Figure 15) using a torque driver to GE recommended torque. (29 inch/pound)
Figure 14. Card Installation
E-63851
Wabtec Proprietary and Confidential Information 21
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Figure 15. Torque Screws
3. PRE-POWER UP CHECKS
Hazardous voltages are present in this equipment. Ensure the Control Power Switch
(CPS) is in the OFF position and the Generator Field Contactor (GFCO) switch is in the
CUTOUT position before attempting any work on control components. Check that
Capacitor Charge Lights (CCLs) are not illuminated. Use a VOM to VERIFY that no volt-
age is present before touching any terminal. Failure to observe these precautions may
result in injury, death, or equipment damage.
DC Voltage must be measured every time the cabinet doors are opened.
3.1. WIRING CHECKS
The Wiring Checks should be completed during truck build in OEM factory, after final assembly at site, and after
component changes during the life of the truck. Follow OEM procedure for truck assembly prior performing wiring
checks. Wiring checks are completed prior to energizing the OEM supplied 24 Vdc system.
1. Perform visual inspection to verify the proper connection of power and ground cables listed in Appendix A-
1, CABLING, using the drive system schematic and OEM documentation. 
2. Verify torque marks per Truck OEM procedure.
3. Inspect cabling listed in Appendix A-1, CABLING, for signs of physical damage to insulation. 
E-63852
WARNING
WARNING
22 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
4. Complete sign off for each power cable and ground listed.
5. Verify there are no inadvertent grounds on the power supply and speed sensors using a Digital Multimeter set to
ohms to measure the power supply outputs listed in Appendix A-2, POWER SUPPLY CHECKS to ground. A hard
ground is value less than 100 ohms to ground.
NOTE: These checks are performed in OEM supplied aux box.
3.2. CONFIGURATION MANAGEMENT
Documenting the serial numbers of GE components on the truck initially and tracking changes to the truck configu-
ration during maintenance, rebuild, and failures over the life of the truck is critical to aid in troubleshooting issues. 
Appendix D., KEY SERIAL NUMBERS includes a list of serial numbers for both the 250T, 320T truck so use only the
serial numbers appropriate for the specific truck. The schematic includes a layout that shows the location of the
components within the 17KG551. Use the list in Appendix D., KEY SERIAL NUMBERS to develop maintenance track-
ing for changes in configuration over the life of the truck.
3.3. GENERAL CLEAN-UP AND INSPECTION
1. Verify all GE equipment is properly mounted per OEM requirements.
2. Verify CGB and WTB blower grounding by measuring ohm value from blower frame to control cabinet, typically
should be less than 1 ohm.
3. Verify areas around blower inlets and outlets are free of debris.
4. Verify speed sensor lock wires for Control group blower, wheel motor blower, and GEB style wheels are installed.
5. Perform general inspection inside all open doors and covers and perform housekeeping to remove any dirt,
dust, or debris.
6. Verify that no moisture is present inside GE equipment and if there is any found contact GE ASM for remediation.
4. TRUCK INITIAL CHECKOUT
Hazardous voltages are present in this equipment. Ensure the Control Power Switch
(CPS) is in the OFF position and the Generator Field Contactor (GFCO) switch is in the
CUTOUT position before attempting any work on control components. Check that
Capacitor Charge Lights (CCLs) are not illuminated. Use a VOM to VERIFY that no volt-
age is present before touching any terminal. Failure to observe these precautions may
result in injury, death, or equipment damage.
Hazardous voltages are present in this equipment. Use caution and avoid touching
any energized equipment when the door to the Low Voltage area is open. Failure to do
so may result in death or serious personal injury.
Electric shock can cause serious or fatal injury. To avoid such injury, personnel should
take and observe proper precautions when making system adjustments or performing
system or component electrical tests.
WARNING
WARNING
WARNING
Wabtec Proprietary and Confidential Information 23
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Only trained personnel should perform ground detection verification tests. Attempting
these tests without proper training may result in injury or death.
The Truck Initial Checkout should be completed during truck build in OEM factory, after final assembly at site, and
after major component and or wiring changes during the life of the truck. Prior to starting the Truck Initial Checkout,
complete 3.1., WIRING CHECKS.
Appendix B., TRUCK INITIAL CHECKOUT is used to document that the Truck Initial Checkout tasks are completed.
4.1. LOW VOLTAGE POWER SUPPLY CHECKS
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 precau-
tions could damage electronic components mounted on them. Also, when transport-
ing or storing these cards, industry recommended special static electricity proof
containers must be used.
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.
4.1.1. Preparation for Power Supply Check
1. Open the door to the Low Voltage area to access the switch panel switches CPS and GFCO.
2. Remove power by setting CPS to OFF and GFCO to CUTOUT.
3. Open OEM BATTSW.
4. Remove the 50 amp control circuit system fuse (BATFU) located on the upper left wall of the low voltage cabinet.
4.1.2. 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.
4.1.2.1. 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 battery voltage (less than 30 VDC) to ground (battery com-
mon or negative), and the other side should read 0 VDC to ground (battery common or negative).
2. Verify there are no improper back feeds from the OEM wiring by verifying the DSC Fuse and card lights remain
off and the fuse lights on the control power distribution module should be off. 
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.
WARNING
CAUTION
CAUTION
24 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
4.1.2.2. System Power Supply
Battery input to FH46 Power Supply will have battery voltage applied to it if the key
switch is OFF, the battery disconnect is closed, and the control power switch is OFF.
The INPUT LED will remain lit and all other LEDs will be off. Failure to observe these
precautions may result in serious personal injury or death.
The FH46 module has internal capacitors. Opening the 17FH46 module may cause
serious personal injury or death.
1. Turn the Control Power Switch ON (CPS, located in the switch panel on the outside right of the main control cab-
inet).
2. On the 17FH47 Power Supply (located in control area of the DSC panel), view the green status LEDs. Verify that all
five LEDs (+15V, –15V, +5.1V, +24V, –24V) are illuminated.
3. The control power distribution panel located in the LV compartment has blade style fuses with a green LED
located next to each fuse. These LEDs indicate whether the fuse is blown or not. If the LED is not lit, the fuse
needs replaced. Verify that for each fuse that the correspondingLED is lit. Confirm both blades of blade style
fuses are correctly inserted into sockets.
4. The DSC Panel has 4 fuses for the wheel motor speed sensor +15Vdc speed sensor power. The blade style fuses
have a green LED located next to each fuse. These LEDs indicate whether the fuse is blown or not. If the LED is
not lit, the fuse needs replaced. Verify that for each fuse that the corresponding LED is lit. Confirm both blades of
blade style fuses are correctly inserted into sockets.
4.1.2.3. VID Power
Check the VID panel is illuminated.
4.2. VERIFY GE DRIVE SYSTEM SOFTWARE REVISIONS
Failure to verify CCL1, CCL2, CCL3, and CCL4 are off prior to starting inverter download
may cause equipment damage.
Do not cycle power once application of software starts to download as equipment
damage may result.
Ensure that all Mine, OEM, and GE safety procedures are followed during truck soft-
ware installation. Ensure the truck is parked in a safe location with the Park Brake
applied and GF Cutout switch is in the CUTOUT position (down), which places propul-
sion system in REST mode. Failure to observe these precautions may result in death or
serious personal injury, as well as equipment damage and inadvertent truck move-
ment.
1. Determine target software versions for GE Drive System Components. Note, the latest released software revi-
sions should be the target and users should check for updates biannually at a minimum.
a. In OEM Factory, use OEM BOM to determine versions to load.
WARNING
WARNING
CAUTION
CAUTION
WARNING
Wabtec Proprietary and Confidential Information 25
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
b. In Field, use OEM Parts and Service News to determine target versions.
2. Determine current version of software loaded on DSC, VID, and quantity (7) Inverters using SOFTWARE VER-
SIONS.
3. If target software and current versions of software are not equal then load target version of software.
a. If OEM Factory, use GE Software Modification Instructions for target software.
b. If Field, use procedure defined in OEM Parts and Service News for target software.
4. Using Appendix B., TRUCK INITIAL CHECKOUT Software Versions, document that the target software has been
installed.
4.3. SETUP AND CONFIG DSC
Ensure the correct Configuration software is loaded into the truck CPUs. Loading the
wrong Configuration software may result in improper truck operation which may
endanger personnel and damage the truck. If the correct Configuration file require-
ments are uncertain, contact GE OHV Representatives.
The DSC CPU needs to be setup to define the truck model that the 17KG551 with 17FL489 panel is installed on. 
1. Perform SETUP DSC. 
2. Perform CONFIGURATION OF DSC.
3. Using Appendix B., TRUCK INITIAL CHECKOUT Software Versions, document that setup and config has been com-
pleted.
4.3.1. Communication Checks
Prior to doing IO checks the various truck controllers should have the proper software loaded and the device should
be powered and communicating on respective networks. Follow OEM procedures to update and power up all com-
munication networks.
1. Verify CAN COMMUNICATION.
2. Verify ETHERNET COMMUNICATION.
Communication Monitoring Ethernet Network
3. Using Appendix B., TRUCK INITIAL CHECKOUT CAN communication and Ethernet communication, document that
the devices listed in Appendix B., TRUCK INITIAL CHECKOUT are communicating
4.3.2. Truck settings
1. Set TRUCK ID. 
2. Set TIME DATE.
3. Set PEDAL CALIBRATION.
WARNING
26 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
4. Prior to proceeding to additional checkout steps, validate there are no active events
5. Using Appendix B., TRUCK INITIAL CHECKOUT Truck Settings, document that these steps are completed
4.3.3. Truck OEM Input and Output Checkout
Electric shock can cause serious or fatal injury. To avoid such injury, personnel should
take and observe proper precautions when making system adjustments or performing
system or component electrical tests.
Only trained personnel should perform control tests. Attempting to perform control
tests without training may result in injury or death.
1. Using the DISPLAY TEST, verify the various CAB IO that is sent from GE to OEM RPC.
2. Using the I/O MONITORING, verify that the digital, analog, and temperature inputs are functioning properly by
exercising those inputs at the source devices. Using the I/O MONITORING, verify that the outputs pick up and
changes state at the OEM destination. For outputs that need to be forced to change the state, use the console
method IO test.
3. Using Appendix B., TRUCK INITIAL CHECKOUT Truck OEM Input and Output Checkout, document that these steps
are completed.
4.4. CIRCUIT CONTINUITY, 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.
NOTE: Primary DC link voltage measurements need to be done with the control power off as the primary DC link
is charged to approximately 3Vdc when de-energized and the control power is on due to the interaction of the
primary H-bridge gate driver modules.
NOTE: Secondary DC link voltage measurements need to be done with the control power off as the secondary DC
link is charged to approximately 0.2Vdc when de-energized and the control power is on due to the interaction of
the Cooling Blower Inverter gate driver modules.
NOTE: If wheel motors are not mounted and wired, ensure the wheel motor power cables are insulated from per-
sonnel and the truck body.
4.4.1. Materials Required
• None
4.4.2. Special Tools And Processes Required
• Multimeter – minimum CAT III 1000V
WARNING
WARNING
Wabtec Proprietary and Confidential Information 27
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
4.5. MEGGER TEST FOR GROUNDS
The control equipment circuitry is classified in three major categories: Alternator field circuit, primary power circuit
and secondary power circuit. 
NOTE: If wheel motors are not mounted and wired, ensure the wheel motor power cables are insulated from per-
sonnel and the truck body.
NOTE: it is suggested that the Secondary Power Circuit not be meggered unless required by local regulations or
necessary for fault finding, because the Cooling Blower Inverter connections to the secondary link bus bar need
to be removed and isolated in order to perform the megger procedure on the secondary power components.
• Also, the procedure does not instruct to remove the three phase blower connections out of the CBI’s. Blower
circuits are instructed to be measured individually and will be relatively low due to the CBI internal VAM
(voltage attenuation module) connections.
• Each CBI has ground fault detection functionality that can detect a ground fault anywhere in the secondary
power circuit. Therefore, there is very little chance that a ground fault on the secondary power circuit will
not be detected by the control system.
All circuit categories must be separately prepared for megger testing.
Hazardous voltages may be present in this equipment even if the engine and Capaci-
tor Charge Lights are off. Use measurement and protective equipment rated for 2000
VDC minimum to verify that no voltage is present before touching any terminal. Verify
functionality of the measurement equipment using site-approved procedures both
before and after performing control group measurements. Failure to observe these
precautions may result in death or serious personal injury.
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
Personnel must not touch and remain clear of all components, cables, or terminals
during and after meggertest due to electrical hazard. Failure to observe these precau-
tions may result in death or serious personal injury.
Use a megger with a discharge setting. Failure to do so may result in death or serious
personal injury.
The DC Link will hold a capacitor charge after megger testing the main power circuit.
Allow sufficient time for it to discharge. Failure to observe these precautions may
result in death or serious personal injury.
A successful megger test must be performed on the power circuits before attempting a
ground circuit test. If a ground exists when the test ground is introduced, the intro-
duced ground wire may melt. Always perform the megger test to avoid introducing
another ground in the power circuit. Failure to observe these precautions may result
in death or serious personal injury.
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
28 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
DC Voltage on capacitors must be measured every time the cabinet doors are opened.
4.5.1. Materials Required
• Quantity 5 x small gage wire jumpers each individually labeled 1 through 5.
NOTE: Labeling jumpers allows for precise tracking of the jumpers particularly when the megger test is com-
plete.
• Quantity 8 x pieces of PTFE (Teflon) board. Each 0.03” thick and approximately 1.5” width x 3” height.
NOTE: This is only required if performing megger procedure on the Secondary Power Circuit.
4.5.2. Special Tools And Processes Required
• Personal Protective Equipment (PPE) for working with 500 VDC.
• Megohm Meter - minimum CAT III 1000V.
• Torque wrench capable of providing 14 lb-ft with ½ inch socket.
NOTE: This is only required if performing megger procedure on the Secondary Power Circuit.
4.5.3. Preparation For Megger Test
Perform the following procedures indicated by the instructions to prepare for a megger test.
4.5.3.1. General
Follow any and all local and site-specific procedures and requirements for working on OHV equipment. Verify that:
1. The diesel engine is shutdown, the Park Brake is set and the truck is properly chocked.
2. The Main Battery switch is open.
3. Isolate the truck from access by people not performing the megger procedure.
4. The generator field is cutout via the GFCO switch (in down position) in the Low Voltage Area of the control cabi-
net. Refer to Figure 2.
5. Ensure all components resistance measurements to the common Deck Ground Point are 1 ohm or less.
6. Remove VAM1-4 output connectors (located in VAM / GF compartment) See Figure 16.
7. Remove and isolate wires connected to VAM4 high voltage input terminals VH1-4 (Figure 17).
8. Remove and isolate all connections to both the RTN bus output terminal and GND1 ground block (located in the
Low Voltage compartment)(Figure 18).
9. Remove the CNB connector on the main electronics card rack (located in the Low Voltage compartment) (Figure
19).
10. Remove CCLR1 and 2 CN1 output connectors (located in the Traction Inverter compartment) (Figure 20).
WARNING
Wabtec Proprietary and Confidential Information 29
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Figure 16. VAM1-4 Output Connectors
Figure 17. VAM4 High Voltage Input Terminals
E-63930
REMOVE THESE
CONNECTORS
E-63931
REMOVE AND ISOLATE
THESE FOUR CONNECTORS
30 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Figure 18. RTN Bus Output Terminal And GND1 Ground Block
Figure 19. CNB Connector
E-63932
REMOVE AND ISOLATE
ALL CONNECTIONS FROM
THESE TERMINAL POINTS
E-63933
REMOVE THIS
CONNECTOR
Wabtec Proprietary and Confidential Information 31
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Figure 20. CCLR1 And 2 CN1 Output Connectors
4.5.3.2. Alternator Field Circuit
1. At AFSE, use jumper #1 to connect DC+ terminal to DC- terminal (Figure 21) and verify connection <=1 ohm with
multimeter.
E-63934
REMOVE THESE
CONNECTORS
32 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Figure 21. DC+ And DC- Terminals
4.5.3.3. Primary Power Circuit.
At DCHB main bus, use jumper #2 to connect DCP bus to DCN bus (Figure 22) and verify connection <= 1 ohm with
multimeter.
E-63941
DC+ TERMINAL
DC- TERMINAL
Wabtec Proprietary and Confidential Information 33
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Figure 22. DCP Bus And DCN Bus Locations
4.5.3.4. Secondary Power Circuit (Optional)
NOTE: It is suggested that the Secondary Power Circuit not be meggered unless required by local regulations or
necessary for fault finding, because the Cooling Blower Inverter connections to the secondary link bus bar need
to be removed and isolated in order to perform the megger procedure on the secondary power components.
1. Remove and isolate all the connections to GND9 ground block and remove CCLR3 and 4 CN1 output connectors
(located in the back side of the cooling blower inverter compartment) (Figure 23).
2. Remove CI1, CI2, GI1 and GI2 CBI connections from the SLVB bus bar and insert PTFE board pieces between SLVB
bus bar and CBI terminals (Figure 24). 
3. At SLVB secondary bus, use jumper #3 to connect SDCP bus to SDCN bus (Figure 25) and verify connection <= 1
ohm with multimeter.
E-63942
DCP BUS
DCN BUS
34 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Figure 23. GND9 Ground Block And CCLR3 And CCLR4 Output Connectors
Figure 24. CI1, CI2, GI1, And GI2 Connectors From The SLVB Bus Bar
E-63935
REMOVE THESE
CONNECTORS
REMOVE AND ISOLATE
ALL CONNECTIONS FROM
THIS TERMINAL POINT
E-63936
REMOVE THESE BOLTS
AND SLIDE PTFE BOARD
IN BETWEEN THE BUS
BAR AND CBI CONNECTIONS
Wabtec Proprietary and Confidential Information 35
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Figure 25. SDCN Bus And SDCP Bus Locations
4.5.4. Megger Test Procedure
Personnel must not touch and remain clear of all components, cables, or terminals
during and after megger test due to electrical hazard. Failure to observe these precau-
tions may result in death or serious personal injury.
4.5.4.1. Alternator Field Circuit.
This section exposes the following circuits / hardware to the megger voltage and also verifies that these circuits /
hardware are not shorted to the main and secondary power circuits.
• Alternator Tertiary.
• AFSE
• Alternator Field
• GF Contactor
• TH1 (Thyrite)
• R1 (Battery Boost Resistor)
• Power Cabling That Interconnects Circuits / Hardware Listed.
1. At DCHB main bus, use jumper #4 to connect the DCN bus to ground the control group enclosure (ground) and
verify connection <= 1 ohm with multimeter.
E-63943
SDCP BUS
SDCN BUS
WARNING
36 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
2. At SLVB secondary bus, use jumper #5 to connect the SDCN bus to ground the control group enclosure (ground)
and verify connection <= 1 ohm with multimeter..
NOTE: Perform this step even if not performing the Megger Test on the Secondary Power Circuit. 
3. At AFSE, connect the positive megohm meter lead to DC+ terminal and negative lead to the control group enclo-
sure (ground).
4. With megohm meter on 500V setting, megger circuit. Ensure reading is in excess of 1 megohms.
5. Use discharge function on megohm meter to discharge the circuit and verify with multimeter.
6. Remove jumper #4 from the DCN bus to the control group enclosure (ground).
NOTE: Leave jumper #5 connected to the SDCN bus and the control group enclosure (ground).
4.5.4.2. Primary Power Circuit
This section exposes the following circuits / hardware to the megger voltage and also verifies that these circuits / 
hardware are not shorted to the alternator field and secondary power circuits.
• Alternator Stator Windings
• FP (Filter Panel)
• RD (MainRectifier)
• FDR (Filter Discharge Resistor)
• GRR, GRR9 and GRR10 (Ground Detection Resistors)
• LFC1-6 (Main DC Link Capacitors)
• All Chopper Modules
• All Retard Grid Resistors
• All Traction Inverter Phase Modules.
• Both Traction Motor Stator Windings
• PB1/2 (Primary H-bridge modules)
• SLT Primary Winding (H1 / H2)
• Power Cabling And Bus Work That Interconnect Circuits / Hardware Listed.
1. At AFSE, use Jumper #4 to connect the DC+ terminal to the control group enclosure (ground) and verify connec-
tion <= 1 ohm with multimeter.
NOTE: Jumper #5 should still be connected between the SDCN bus and the control group enclosure (ground) from
the previous Alternator Field Megger test.
2. At DCHB main bus, connect the positive megohm meter lead to the DCP bus and negative lead to the control
group enclosure (ground).
3. With megohm meter on 500V setting, megger circuit. Ensure reading is in excess of 1 megohms.
4. Use discharge function on megohm meter to discharge the circuit and verify with multimeter.
Wabtec Proprietary and Confidential Information 37
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
5. Remove jumper #5 from the SDCN bus and the control group enclosure (ground).
NOTE: Leave jumper #4 connected to the AFSE DC+ bus and the control group enclosure (ground) if performing
the Megger Test on the Secondary Power Circuit. Otherwise remove it also and skip the next section.
4.5.4.3. Secondary Power Circuit (Optional)
4.5.4.3.1.Secondary DC Link Circuit
This section exposes the following circuits / hardware to the megger voltage and also verifies that these circuits /
hardware are not shorted to the alternator field and primary power circuits.
• SLT Secondary Winding (X1 / X2)
• SB (Secondary H-Bridge Module)
• SGRR1-4 Secondary Link Discharge Resistors
• SLCF1-7 Secondary Link Capacitors
• Power Cabling And Bus Work That Interconnect Circuits / Hardware Listed.
1. At DCHB main bus, use jumper #5 to connect the DCN bus to the control group enclosure (ground) and verify
connection <= 1 ohm with multimeter.
NOTE: Jumper #4 should still be connected between AFSE DC+ terminal and the control group enclosure (ground)
from previous Primary Power Circuit Megger test.
2. At SLVB secondary bus, connect the positive megohm meter lead to SDCP bus and negative lead to the control
group enclosure (ground).
3. With megohm meter on 500V setting, megger circuit. Ensure reading is in excess of 1 megohms.
4. Use discharge function on megohm meter to discharge the circuit and verify with multimeter.
5. Remove jumper #4 from the AFSE DC+ terminal and the control group enclosure (ground) and jumper #5 from
the DCP bus and the control group enclosure (ground).
4.5.4.3.2.Cooling Blower Circuits
The cooling blower circuits must be meggered individually since the CBI’s are disconnected from the Secondary DC
Link.
NOTE: This procedure does not suggest that the three phase connections to the blower motors be removed and
isolated. However, the megger readings will in general be lower than expected due to the fact that the internal
CBI VAM circuits are still connected to the output terminals. These will be very low if the CBI secondary link bus
connections are not removed and isolated.
38 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
This section separately exposes the following circuits / hardware to the megger voltage.
• CI1 CBI, CGB cooling blower motor stator and power cabling.
• CI2 CBI, WTB cooling blower motor stator and power cabling.
• GI1 CBI, GB1 cooling blower motor stator and power cabling.
• GI2 CBI, GB2 cooling blower motor stator and power cabling.
1. At the CI1 CBI, connect the positive megohm meter lead to CI1 T1 terminal and negative lead to the control
group enclosure (ground).
2. With megohm meter on 500V setting, megger circuit. Ensure reading is a minimum of 0.3 megohms.
3. Use discharge function on megohm meter to discharge the circuit and verify with multimeter.
4. At the CI2 CBI, connect the positive megohm meter lead to CI2 T1 terminal and negative lead to the control
group enclosure (ground).
5. With megohm meter on 500V setting, megger circuit. Ensure reading is a minimum of 0.3 megohms.
6. Use discharge function on megohm meter to discharge the circuit and verify with multimeter.
7. At the GI1 CBI, connect the positive megohm meter lead to GI1 T1 terminal and negative lead to the control
group enclosure (ground).
8. With megohm meter on 500V setting, megger circuit. Ensure reading is a minimum of 0.3 megohms.
9. Use discharge function on megohm meter to discharge the circuit and verify with multimeter.
10. At the GI2 CBI, connect the positive megohm meter lead to GI2 T1 terminal and negative lead to the control
group enclosure (ground).
11. With megohm meter on 500V setting, megger circuit. Ensure reading is a minimum of 0.3 megohms.
12. Use discharge function on megohm meter to discharge the circuit and verify with multimeter.
4.5.5. Restore Circuitry
If no faults were found, remove jumpers #1-5 and reconnect all wires, cables and hardware previously disconnected
for this test as follows:
1. Remove jumpers #1-5 from the control group and ensure all five jumpers are recovered and accounted for.
2. Restore the following only if the Secondary Power Circuit Megger Test was performed.
a. Remove the PTFE board and restore CI1, CI2, GI1 and GI2 CBI connections to the SLVB bus bar. Use torque
wrench to torque bolts to 14 lb-ft.
b. Reconnect the CCLR3 and 4 CN1 output connectors.
c. Reconnect wires to GND9 ground block.
Wabtec Proprietary and Confidential Information 39
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
3. Reconnect CCLR1 and 2 CN1 output connectors.
4. Reconnect the CNB connector on the main electronics card rack.
5. Reconnect wires to GND1 ground block.
6. Reconnect wires and cable to the RTN bus output terminal.
7. Reconnect wires to VAM4 high voltage input terminals VH1-4.
8. Reconnect VAM1 – 4 output connectors.
9. The generator field can now be cut-in if desired via the GFCO switch provided it is safe to do so.
NOTE: Leave in cutout position if immediately performing tests in subsequent sections of this VTI.
10. The Main Battery switch can now be closed if desired provided it is safe to do so.
4.5.6. 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 megger again.
NOTE: Refer to the overall OEM provided system schematic to obtain the most convenient points for subsection
isolation.
NOTE: Subdividing the grounded section should continue until the ground is isolated in a particular cable or
piece of equipment. Then take the appropriate measures.
4. If the ground occurs in a motorized wheel or alternator, the unit should be checked by removing all connections
and megger the circuit again.
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 re-megger
the Dynamic Retarding Assembly.
40 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
8. If the ground is still present, thoroughly inspect the DynamicRetarding 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 re-
megger 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.
5. ENGINE RUNNING CHECKS
A successful megger test must be performed on the power circuits before attempting a
ground circuit test. If a ground exists when the test ground is introduced, the intro-
duced ground wire may melt. Always perform the megger test to avoid introducing
another ground in the power circuit. Failure to do so may result in equipment damage.
Prior to Self Load (Loadbox) all prior checks must be completed.
NOTE: Throughout this section text is formatted in order to aid in usage of this manual. Instructions containing
font that is ALL CAPITALS AND ITALIZED or font that is ALL CAPITALS AND BLUE are links that will take you to other
sections of this manual for further information.
The following tests are performed with the engine running. The checks and setup procedures described in section
4., TRUCK INITIAL CHECKOUT and 3., PRE-POWER UP CHECKS must be successfully completed immediately before
performing the test procedures described in the following sections. 
Appendix C., ENGINE RUNNING TESTS is used to document that the Engine Running Checks are completed.
5.1. INITIAL CHECKS
Many GE OHV AC propulsion systems have a mode of operation called REST that is entered automatically when the
operator cab rest switch is placed in the REST position. The OEM has removed the rest switch from the Cab on
17KG551 systems. The GF Cutout switch can be used to put the system in rest mode.
1. Put GF cutout in the cutout position.
2. Verify that all doors and covers to GE equipment are properly secured
During Truck OEM factory checkout the wheel motors may not be installed on the truck. If the wheel motors are not
installed then do the following prior to running the engine.
3. Cut out inverters TMC1 and TMC2 (GEK-91842, HUMAN MACHINE INTERFACE (HMI) MANUAL).
4. Wheel motors are not required and may not be mounted during this test. If wheel motors are not mounted and
wired, ensure the wheel motor power cable terminals are insulated from personnel and the truck body.
CAUTION
CAUTION
Wabtec Proprietary and Confidential Information 41
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Follow Truck OEM and Engine manufacturer procedures to verify proper operation of engine and truck subsystems
prior to continuing this checkout procedure. On completion of the OEM checkout, stop the engine.
5.2. BATTERY BOOST CIRCUIT VERIFICATION
Only trained personnel should perform control tests. Attempting to perform control
tests without training may result in injury or death.
Follow all local safety procedures mine procedures, verify personnel are clear of the
truck, and truck components are prepared for engine start and Self Load (Loadbox).
Failure to do so may result in injury, death, or equipment damage and truck or drive
system component damage.
This procedure MUST be performed exactly as written. Failure to do so may result in
personal 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. The truck should be parked on level ground with wheels chocked, the Directional Control Lever in park, and the
engine shutdown. The park brake applied.
2. All foreign material, tools, and loose parts must be removed from the control cabinets and the retarder assem-
bly. Remove any material around or under the retarder assembly that may be drawn into the assembly prior to
energizing the DC Link.
3. Place the GF Cutout switch into the NORMAL position.
Hazardous voltages are present in this equipment. Ensure the Control Power Switch
(CPS) is in the OFF position and the Generator Field Contactor (GFCO) switch is in the
CUTOUT position before attempting any work on control components. Check that
Capacitor Charge Lights (CCL1, CCL2, CCL3, and CCL4) are not illuminated. Use a VOM
to VERIFY that no voltage is present before touching any terminal. Failure to do so may
result in injury, death, or equipment damage.
DC Voltage on capacitors must be measured every time the cabinet doors are opened.
4. Verify the Capacitor Charge Lights (CCL1, CCL2, CCL3, and CCL4) are off.
5. Connect a voltmeter (IEC-1010-1 — CAT III/1000 V meter) across battery boost R1 resistor. R1 is located in the
power portion in the control cabinet. Connect the voltmeter positive lead to R1 resistor terminal with wire BAT
connected. Connect the voltmeter negative lead to R1 resistor terminal with wire F101 connected.
6. After connecting the voltmeter, secure the cabinet access door closed without cutting the voltmeter wires.
7. Ensure the truck control power for the drive system is ON (engine not running). Put the truck in Rest by using
WebPTU config\switches.
8. Start the diesel engine. The Directional Control Lever must be in park to allow the engine start sequence. Alter-
nator excitation begins when the propulsion mode changes to READY mode.
WARNING
WARNING
WARNING
WARNING
WARNING
42 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
9. Transistion the drive system mode from Rest to Ready by deselecting rest in WebPTU config\switches
10. The voltmeter will read approximately 18 volts momentarily and drop to zero (0) volts during the battery boost
portion of alternator excitation. 
NOTE: It may be helpful to set the digital multimeter to max/min setting to be able to see the voltage during the
brief time of battery boost.
a. If the maximum voltmeter reading is approximately 18 volts, continue to completion of this procedure.
b. If the maximum voltmeter reading is significantly different (higher or lower) from 18 volts or does not drop
back to zero, troubleshoot the battery boost circuit including battery volts, wiring, R1 connections, until
problem is resolved. Repeat the check after the problem has been addressed.
11. Verify the Capacitor Charge Indicating Lights (CCL1, CCL2, CCL3, and CCL4) LEDS are all lit.
12. Verify engine speed changes by depressing accelerator pedal.
13. Shutdown the engine.
14. Place the GF Cutout switch into the CUTOUT position (down).
15. Verify the Capacitor Charge Indicating Lights (CCL1, CCL2, CCL3, and CCL4) are off. A short time interval may be
required to allow the capacitor charge level to bleed down to a safe level.
Hazardous voltages are present in this equipment. Ensure the Control Power Switch
(CPS) is in the OFF position and the Generator Field Contactor (GFCO) switch is in the
CUTOUT position before attempting any work on control components. Check that
Capacitor Charge Lights (CCL1, CCL2, CCL3, and CCL4) are not illuminated. Use a VOM
to VERIFY that no voltage is present before touching any terminal. failure to do so may
result in injury, death, or equipment damage.
16. When the Capacitor Charge Lights (CCL1, CCL2, CCL3, and CCL4) are off, disconnect the voltmeter from R1 resis-
tor and close and secure the cabinet access door.
17. Place the GF Cutout switch in the normal position.
5.3. VI TEST
Only trained personnel should perform control tests. Attempting to perform control
tests without training may result in injury or death.
During DC Link Initialization a systematic approach is taken to powering the traction DC link, the blower secondary
link, and each blower. This test is integral to the control system. Events are generated to aid the user to identifyand
troubleshoot issues. Blowers are energized one by one and the speed feedback for that blower is verified.
1. Follow OEM procedures to run engine with Drive System in ready mode.
2. Verify no new events are logged.
3. Verify that blowers are spinning in proper direction by checking. Note, individual blowers can be cut out to iso-
late equipment for troubleshooting or verifying air flow.
WARNING
WARNING
Wabtec Proprietary and Confidential Information 43
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
a. WM Cooling Blower, air should be exiting the axle box and the 17ET38 transformer outlet. Note, blower has
a direction arrow on impeller near inlet screen.
b. Control Group Cooling Blower, air should be exiting the control group. Note, blower has a direction arrow on
impeller near inlet screen.
c. Grid blower 1, air should be blown across the resistors and exiting the outlet.
d. Grid blower 2, air should be blown across the resistors and exiting the outlet.
5.4. CAPACITANCE TEST
Only trained personnel should perform control tests. Attempting to perform control
tests without training may result in injury or death.
The capacitance test measures the system capacitance and checks the ground fault circuit during the discharge of
the capacitors.
1. Initiate the CAPACITANCE TEST.
2. Verify no new events are logged.
5.5. DIRECTIONAL CONTROL LEVER
Verify Directional Control Lever (park/forward/neutral/reverse) operation. Complete this test after wheel motors are
installed. To verify Directional Control Lever:
1. The truck should be parked on level ground with wheels chocked, Directional Control Lever in park, and the
engine running. The GF Cutout switch in the CUTOUT position (down) which places the propulsion system in REST
mode. Verify the System Mode is REST.
2. All foreign material, tools, and loose parts must be removed from the control cabinets and the retarder assem-
bly. Remove any material around or under the retarder assembly that may be drawn in to the deck mounted
blowers, during Self Load Test (Loadbox).
3. Wheel motors are required for this test. 
4. Set the GF Cutout switch in the Normal position (up) which allows the propulsion system to exit REST mode. Ver-
ify the System Mode changes to TEST, then READY within one minute.
5. With the service brakes applied, move the Directional Control Lever to FORWARD and verify torque (command
and feedback) is present on each inverter (TQCMD1, TQCMD2, and TRQFB1, TRQFB2).
6. With the service brakes applied, move the Directional Control Lever to REVERSE and verify torque (command
and feedback) is present on each inverter (TQCMD1, TQCMD2, and TRQFB1, TRQFB2).
7. Verify no EVENTS are logged.
5.6. LOSS OF J1939 COMMUNICATION
Hazardous voltages are present in this equipment. Use caution and avoid touching
any energized equipment when the door to the Low Voltage area is open. Failure to do
so may result in death or serious personal injury.
WARNING
WARNING
44 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Engine speed reference is sent from the GE Drive System to the Engine over the J1939 network. During loss of J1939
communication between the two systems the engine will respond to two hard wired outputs from the drive system.
The outputs are driven by the accelerator pedal position.
1. Break J1939 network connection in GE Control DSC CAN-1 located in the LV compartment of the 17KG551.
2. With engine running, verify engine rpm is idle speed.
3. Engage accelerator pedal to approximately 50% and verify that the engine rpm is at least 1180 RPM.
4. Fully engage the accelerator pedal and verify the engine rpm is 1930 RPM.
5. Restore GE Control DSC CAN-1 network.
6. Verify no active events.
5.7. ENGINE WARNING (RED LIGHT) 
The engine warning is a J1939 CAN signal from the ECM that indicates fault detected in the engine. When engine
warning is on while the engine is running, the GE Drive System shall log an accel inhibit fault. Within 10 seconds of
the engine warning light being illuminated, this restrictive fault will reduce the load on the engine to the minimum
possible while maintaining the ability to provide retarding torque. 
1. Following Truck OEM or Engine builder procedures, Run engine with GE Drive System DC Link Energized (No GF
Cutout)
2. Following Truck OEM or Engine builder procedures, generate an engine warning
3. Verify that event 619 is active
4. Verify that NOPROP is active
5. Remove Engine warning
5.8. BLOWER TEST AND AXLE BOX PRESSURE SWITCH
Only trained personnel should perform control tests. Attempting to perform control
tests without training may result in injury or death.
Blower test will run each blower to full speed and verify blower operation. The axle box pressure switch is mounted in
the rear case. The cooling air supply is provided by the Wheel Motor cooling blower. The DSC-DI07 input should be
true when Axle blower speed > 2100 rpm and should be false at Blower speeds < 50 rpm. If wheel motors are not
installed on the truck then the lack of back pressure may cause the axle box pressure switch to not operate correctly.
Table 3. J1939 Communication
IO Description Output
ECM Low Idle 
Governor
At Least 
1180 RPM
1930 RPM 1930 RPM
Engine ISC High Speed DSC-DO17 Off Off On On
Engine ISC Medium Speed DSC-DO18 Off On Off On
WARNING
Wabtec Proprietary and Confidential Information 45
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
1. Verify that the axle box pressure switch DSC-DI07 is false when the engine is stopped. If the switch is not false,
verify the wiring.
2. With Engine running, wheel motors installed, and drive system energized, use BLOWER TEST to verify when the
WM Blower is above 2200 RPM that DSC-DI07 is True. If wheel motors are not installed use Blower Test to verify
that blowers pass the test but the pressure switch will not activate.
3. If the switch needs to be adjusted then follow Truck OEM procedures for accessing and adjusting the pressure
switch. Note, pressure switch adjustments should be made in ¼ turn increments and then the system should be
rechecked. Note clockwise adjustment is to increase the pressure required for the switch to pick up and counter
clockwise is to decrease the pressure required to pick up. 
5.9. SELF LOAD (LOADBOX) TEST PROCEDURE
Prior to Self Load (Loadbox) all prior checks must be completed.
Follow all local safety procedures, mine procedures, verify personnel are clear of the
truck, and truck components are prepared for engine start and Self Load (Loadbox).
Failure to observe these precautions may result in death or serious personal injury,
and truck or drive system component damage.
NOTE: OEM parasitic loads like the radiator fan should be forced to an on state to improve consistency in bench-
marking the engine.
1. Perform a LOADBOX with a slow deliberate press of the accerlator pedal while monitoring active events. If
events occur during loadbox then stop and troubleshoot the issue.
2. Perform a LOADBOX with a snap throttle followed by 2 minutes at full load. Record HP Alt In.
3. Exit loadbox.
4. Use the Engine Warm Switch in OEM Operator Cab and verify that the engine is loaded.
5. Perform a DATA CAPTURE quick to save the truck data.
Removing the flash drive while the STATUS LEDs are flashing may cause corruption to
the files on the flash drive.
5.10. POWER MODULE VIBRATION MEASUREMENTS
The following measurements are used to characterize the power module vibration levels at the alternator.
Only trained personnel should perform control tests. Attempting to perform control
tests without training may result in injury or death.
Follow all local safety procedures mine procedures, verify personnel are clear of the
truck, and truck components are prepared for engine start and Self Load (Loadbox).
Failure to do so may result in injury, death, or equipment damage and truck or drive
system component damage.
CAUTION
WARNINGCAUTION
WARNING
WARNING
46 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
1. Prior to starting the engine put the control system in rest mode by putting the propel lockout in the lockout posi-
tion and then follow OEM procedures to run engine.
2. Attach vibration probe magnetic base to 3 o’clock of the alternator framehead to collect the HORIZONTAL (Fig-
ure 26) vibration reading. Make sure the probe is firmly attached.
3. Using the console, type in “run speed_sweep” followed by enter that will run each speed with a 30 second dwell
time before going to the next speed. Record the velocity measurement for the 5 speeds using Appendix
C., ENGINE RUNNING TESTS.
4. Relocate the vibration probe magnetic base to the 6 o’clock location on the framehead to collect the VERTICAL
(Figure 26) vibration reading. Make sure the probe is firmly attached.
5. Using the console, type in “run speed_sweep” followed by enter that will run each speed with a 30 second dwell
time before going to the next speed. Record the velocity measurement for the 5 speeds using Appendix
C., ENGINE RUNNING TESTS.
6. Relocate the vibration probe magnetic base to the 3 o’clock location on the framehead flange to collect the
AXIAL (Figure 26) vibration reading. Make sure the probe is firmly attached.
7. Using the console, type in “run speed_sweep” followed by enter that will run each speed with a 30 second dwell
time before going to the next speed. Record the velocity measurement for the 5 speeds using Appendix
C., ENGINE RUNNING TESTS.
8. Remove the vibration probe magnetic base from the unit.
Figure 26. Vibration Probe Placement
E-60714
HORIZONTAL
AXIAL
VERTICAL
Wabtec Proprietary and Confidential Information 47
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
6. GLOSSARY OF TERMS, ACRONYMS, AND ABBREVIATIONS
The following is a list of typical terms, acronyms, and abbreviations used in this publication. Not all systems have all
options detailed in the list. 
 
Table 4. Glossary of Terms 
Term Description
A3PV or AP3-
VOLT 
Alternator Three-phase voltage output as measured by a VAM unit. Refer to electrical schematics 
for VAM assignments. 
ACCEL-SEL Indicates the accel pedal request level. 
ACCINHI Accel Inhibit circuit prevents truck propulsion when the text is highlighted. 
ACCPDL Indicates voltage level feedback from the Accel Pedal. 
AFCURREF Alternator excitation field current reference (command). 
AF-I Alternator excitation field current level (actual). 
AFSE Alternator Field Static Exciter (AFSE) panel regulates the excitation current in the alternator exci-
tation field. An AFSE turn ON command is indicated when the text is highlighted. 
AFSER Alternator Field Static Exciter Resistor (AFSER) is used in the battery boost circuit to current limit 
AFSE battery boost command circuit. 
AFSET The AFSE temperature in degrees C. 
ALT Alternator is a salient-pole, three-phase, Y-connected, AC machine that is mounted solidly to the 
diesel engine and is driven by the engine crankshaft. The alternator provides electrical power for 
propulsion and control systems. 
ALTFAMPS Indicates the Alternator excitation field current (actual). 
ALTFVOLTS Indicates the Alternator excitation field voltage (actual). 
AMBT or AMB-
TEMP 
Ambient Temperature (AMBTEMP or AMBT). Refer to AMBTS. 
AMBTS Ambient Temperature Sensor (AMBTS) measures environmental temperature the truck is operat-
ing in. 
ANALOG I/O 
CARD (DSC) 
DSC Analog Input/Output Card provides signal conditioning for analog signals to/from the 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. 
APINHI Displays the Accel pedal input voltage. 
AUTON Indicates autonomous mode is requested (OEM specific application). 
AXLEP Indicates Axel Box Pressure (digital switch) is detected in the axle box when the text is highlighted. 
B1_AMPS or 
B2_AMPS 
Indicates the current of Grid Blower 1 or, if equipped, Grid Blower 2. 
B1_VOLTS and 
B2_VOLTS 
Indicates the voltage present on Grid Blower 1 and, if equipped, Grid Blower 2. 
BAROP Barometric Pressure Sensor (BAROP) measures the environmental barometric pressure the truck is 
operating in. 
BAT Control battery voltage level. 
BATFU Battery Power Fuse provides overload protection to the control equipment. 
48 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
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 (BFC) Assembly is used to temporarily sustain control power to the elec-
tronics panels in the presence of battery voltage dips and short term outages. 
BFCR Battery Filter Capacitor Resistor is used to limit inrush current to the Battery Filter Capacitor 
Assembly. 
BM1, BM2 Blower Motors No. 1 and No. 2 (if equipped) are DC motors located within the Dynamic Retarding 
Assembly. The motors drive two blowers (fans) each. The blowers provide cooling air for the 
Retarding Resistors in the Dynamic Retarding Assembly during dynamic retarding operations and 
self-load testing. 
BM1I, BM2I Grid Blower Motors No. 1 and No. 2 (if equipped) Current Measuring Modules (LEM) is used to mea-
sure the DC current flow through the grid blower motors. 
BODYDWN Indicates the dump body is down when the text is highlighted. 
BRAKEON Indicates either the service brake is depressed or the wheel brake lock (dump brakes) are applied 
when the text is highlighted.
BRAKES Indicates either the service brake is depressed or the wheel brake lock (dump brakes) are applied 
when the text is highlighted.
BRKPRESS Service brake pressure.
BRKTSTREQ Indicates the operator has requested the Pre-shift Brake Test when the text is highlighted. 
CAPCP Indicates the Capacitor Test Mode is complete when the text is highlighted. 
CAPR Indicates a Capacitor Test is required when the text is highlighted. 
CAPTST Indicates the Capacitor Test Mode is active when the text is highlighted. 
CBI Cooling Blower Inverters
CCF1, CCF2 Line Filter Capacitor connected across the DC Link. 
CCL1, CCL2 Capacitor Charge Indicating Light 1 & 2 are illuminated when hazardous power is on the DC Link 
bus. 
CCL3, CCL4 Capacitor Charge Indicating Light 3 & 4 are illuminated when hazardous power is on the second-
ary DC link.
CF11A & CF11B 
and CF12A, & 
CF12B 
Line Filter Capacitor 11A & 11B and 12A & 12B are filter capacitors on the DC Link bus For Inverter 
1. 
CF21A & CF21B 
and CF22A, & 
CF22B 
Line Filter Capacitor 21A & 21B and 22A & 22B are filter capacitors on the DC Link bus For Inverter 
2. 
CGB Control Group Blower
CGBM1 & 
CGBM2 
Capacitor Grid Blower Motor 1 &, (if equipped) Capacitor Grid Blower Motor 2 (BM2) used for cur-
rent inrush control on the BM1 and BM2 
CGPS Control Group Pressure Switch
CHOP Chopper Modules ON percentage displayed. 
CI1 Cooling Blower Inverter 1
Table 4. Glossary of Terms (Continued)
Term Description
Wabtec Proprietary and Confidential Information 49
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
CI2 Cooling Blower Inverter 2
CM1, CM2, 
CM3, CM4 
Chopper Module No. 1, No. 2, and if equipped, No. 3, No. 4 indicates command to turn ON when 
highlighted. 
CM1A Inverter #1 Phase A Current Sensor
CM1B Inverter #1 Phase B Current Sensor
CM2A Inverter #2 Phase A Current Sensor
CM2B Inverter #2 Phase B Current Sensor
CMAF Current transducer for rotating Alternator excitation field DC current. 
CMCTL Chopper Module control signal. Inverter 2 controls Chopper modules when the text is highlighted. 
CMT Current transducer for tertiary Alternator field AC output.CNFB Indicates CNA - CNF plugs are all connected when the is highlighted. 
CNTRLP Indicates the control cooling blower pressure is OK (ON) when the PTU screen text is highlighted. 
CNX Indicates all CNX plugs are all connected when the text is highlighted. 
CNX1, CNX2, 
CNX3, CNX4, 
CNX5 
The 48 pin round connector plugs for the OEM Auxiliary Box for external control wiring interface 
connections. 
COMMLINK Indicates the communication status. 
CONTROLON Indicates that control power is present when the text is highlighted. 
CPR Control Power Relay (CPR) provides battery power to specific control components. CPR is com-
manded and ON when the text is highlighted. 
CPRD Control Power Blocking Diode provides diode blocking between the control power switch input 
and the control power digital output. 
CPRL Indicates the Control Power relay latch circuit is energized when the text is highlighted. 
CPS Control Power Switch (CPS), along with the key switch, provides battery power for specific control 
components. CPS is commanded and On when the text is highlighted. 
CPSFB Control Power Switch (CPS) feedback. Status is ON when the text is highlighted. 
CPU Central Processor Unit providing sequential functions, calculations, and monitoring of system 
functions. 
CPU CARD 
(DSC) 
System CPU Card provides propulsion control system processing and serial link communication. 
CRNKBAT Indicates the voltage level of the Crank batteries. 
CRUISE Cruise control lever voltage.
CTRLBAT Indicates the voltage level of the Control batteries. 
CUSTOM 1, 2, 3 
or 4 
Selectable custom parameters. 
DAB Dual Active Bridge that is made up of PHB, Transformer, and SHB
DATAST A manual Data Store has been activated to store truck condition by push button when the text is 
highlighted. 
DC LINK The DC Link is power from the traction Alternator 3 phase output after rectification by the Rectifier 
Panel (RD) or Rectifier Diode modules (RDA, B, & C). The DC Link is ON when the text is highlighted. 
Table 4. Glossary of Terms (Continued)
Term Description
50 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
DID Diagnostic Information Display (DID) 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 (DSC-A, 
DSC-B) 
System Digital Input/Output Card provides battery level drive signals to control relays, contactors 
and LEDs; and receives battery level status feedbacks of relays, contactors and switches. 
DIR-SEL Indicates the operator cab directional control lever selection displayed on the PTU screen. 
DISP-LINK Dispatch serial channel communication status. 
DISSPDL If equipped, displays dispatch speed limit. 
DSC Drive System Controller.
DSCLINK State of the LINK charging machine.
DSCMODE Main state of machine mode.
DSPDLON If equipped, indicates the Dispatch Speed Limit is active when the PTU screen text is highlighted. 
ENG_RP Indicates the engine RPM has been raised and Chopper 1 is ON due to an Event restriction. Refer 
to the Event Listing publication. 
ENGCAUTION Indicates an diesel engine CAUTION has been received from the engine controller. 
ENGCMD Engine RPM command from GE to engine.
ENGKILL Indicates an Engine Stop switch has been activated when the PTU screen text is highlighted. 
ENGLOAD% If equipped, the engine load signal displaying 50% for correct engine load. Less than 50% indi-
cates engine overloaded condition, greater than 50% indicates engine unloaded condition.
ENGSPD Indicates diesel engine RPM, measured in the Alternator by ESS. 
ENGSTOP Indicates an engine stop (kill or OFF) switch has been activated manually when the text is high-
lighted. 
ENGSTRTREQ Indicates an diesel engine start request has been received by the Control System when the text is 
highlighted. 
ENGWARN Indicates an Engine Warning has been activated in the engine controller when the text is high-
lighted. 
ESI1 & ESI2 Engine Speed Increase 1 & Engine Speed Increase 2 for OEM specific application displayed. 
ESS Engine Speed Sensor that is mounted on the alternator, which is directly coupled to the engine. 
EWMS Engine Winter Mode Switch (EWMS) provides engine warming RPM during cold weather. EWMS is 
located in the operator cab. 
FORREQ Forward direction request.
FORT Truck is moving forward regardless of direction request.
FULLPAYLD Full payload signal.
GDCP1 & 
GDCP2
Gate Driver Power Supply enabled if highlighted.
GF GF contactor command.
GFAULT Ground fault current.
GFCO GF cutout switch provides a means of mechanically preventing the energizing of the GF contactor, 
thereby providing a means to ensure the DC link is not energized. 
GFFB Generator Contactor auxiliary contact feedback status (ON when the PTU text is highlighted). 
Table 4. Glossary of Terms (Continued)
Term Description
Wabtec Proprietary and Confidential Information 51
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
GFM Gate Firing Module (on AFSE) receives the incoming pulses from the Analog Input/Output Card in 
the Propulsion Control Panel, converts them into appropriate AFSE control signals. 
GFNCO Indicates the GFCO switch is not in the cutout position when the PTU text is highlighted. 
GFR Generator Field Relay (GFR) provides battery power to AFSE for battery boost function. GFR turn 
ON command is indicated when the text is highlighted. 
GFRS Suppression Module limits the transient voltage induced into the battery system whenever power 
to the GFR coil is opened or interrupted. 
GFS Suppression Module limits the transient voltage induced into the battery system whenever power 
to the GF coil is opened or interrupted. 
GI1 Cooling Blower Inverter Grid 1
GI2 Cooling Blower Inverter Grid 2
GRIDI Current sensor measuring the current going to the Grid Box.
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 and 
GRR10 
Ground Resistor 9 & 10 used with GRR to monitor traction motors power circuit grounds. 
GVW Gross Vehicle Weight 
HMI Human Machine Interface
HPADJ Indicates the engine horse power offset adjustment displayed. 
HPLINK Calculated horsepower feedback from the DC Link displayed. 
HYBKT Indicates the hydraulic brake fluid temperature displayed. 
I1LV & I2LV Indicates the DC Link voltage measured by Inverter 1 and Inverter 2 VAM units displayed Refer to 
electrical schematics for VAM assignments. 
INCLINE Incline in Percent grade the truck is currently sitting on.
INV1 TMC CARD Inverter No. 1 Traction Motor Control (TMC) Card controls propulsion and retard power for Inverter 
1 (Inverters 11 and 12) phase modules and Chopper Modules. 
INV2 TMC CARD Inverter No. 2 Traction Motor Control (TMC) Card controls propulsion and retard power for Inverter 
2 (Inverters 21 and 22) phase modules and Chopper Modules (when Inverter 1 is in cutout). 
INV1DID & 
INV2DID 
Inverter shutdown request from the DID panel when the text is highlighted. 
INV1DIS & 
INV2DIS 
Indicates Inverter 1 or Inverter 2 is disabled when the text is highlighted. 
INV1TQFB Indicates the torque feedback (in LB-FT) generated by Inverter 1 displayed. 
INV2TQFB Indicates the torque feedback (in LB-FT) generated by Inverter 2 displayed 
IVTEST Indicate the Control System is in Inverter Test Mode when the is highlighted. 
KEY_CPS Indicates both the Key switch and CPS are ON when the text is highlighted. 
KEYSW OEM Key Switch (KEYSW) activates and deactivates truck systems for operation. Status is ON 
when the text is highlighted. 
LAMPTEST Indicates the operator has requested a operator cab lamp test when the text is highlighted. 
LDBR Indicates a Loadbox Test is required when the text is highlighted. 
Table 4. Glossary of Terms (Continued)
Term Description
52 Wabtec Proprietary and Confidential InformationGEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
LDBX Indicates the Control System is set for Loadbox Mode when the is highlighted. 
LFRPM Indicates the truck left front wheel speed displayed. 
LIMPOK Indicates Limp Mode (an inverter disabled) is active when the text is highlighted. 
LINKI Link Current Sensing Module (LEM) detects the amount of current flow through the DC link (the DC 
bus that connects the rectified Alternator output, Chopper Module/Resistor Grid circuits, and trac-
tion Inverters). 
LINKON or 
LINKONLT 
Indicates the DC Link is powered when the text is highlighted. 
LINKV Indicates DC Link voltage measured by a VAM unit and displayed. 
LINKV-POS Indicates the voltage between the DC Link positive and ground and displayed. 
LOADBRK If equipped, Load Brake switch. Load Brake applied when the text is highlighted. 
LWSPEED Indicate the left rear wheel speed based on Speed Sensor and displayed. Refer to SS1, SS2, SS3, & 
SS4. 
M1RPM & 
M2RPM 
Indicates Motor 1 and Motor 2 rotor RPM displayed. 
MODE1, 
MODE2, 
&MODE3 
Indicates the operating mode of Inverter 1 and Inverter 2 displayed. Operating modes would be 
PWM (1), Patterns (2), or Square Wave (3). 
NHP Indicates the net engine Horse Power from the engine used by the Control System (Gross HP -Par-
asitic) and displayed. 
NOPROPEL Indicates that Propel Mode is not available when the text is highlighted. 
NORETARD Indicates that Retard Mode and Propel Mode are not available when the text is highlighted. 
NEUTRAL Neutral position of the Directional Control Lever.
OEMACCIN Indicates the OEM accel inhibit circuit is preventing propulsion when the text is highlighted. 
OVERPAYLD or 
OLOAD 
If equipped, indicates the truck payload system is over the maximum truck payload when the text 
is highlighted. 
P11A+, P11A-, 
P11B+, P11B-, 
P11C+, & P11C
Inverter 11 Phase Modules A (+ & -), B (+ & -), & C (+ & -) creates 3 phase AC from the DC Link for 
TM1 power when combined with Inverter 12 power. 
P12A+, P12A-, 
P12B+, P12B-, 
P12C+, & P12C
Inverter 12 Phase Modules A (+ & -), B (+ & -), & C (+ & -) creates 3 phase AC from the DC Link for 
TM1 power when combined with Inverter 11 power. 
P21A+, P21A-, 
P21B+, P21B-, 
P21C+, & P21C
Inverter 21 Phase Modules A (+ & -), B (+ & -), & C (+ & -) creates 3 phase AC from the DC Link for 
TM2 power when combined with Inverter 22 power. 
P22A+, P22A-, 
P22B+, P22B-, 
P22C+, & P22C
Inverter 22 Phase Modules A (+ & -), B (+ & -), & C (+ & -) creates 3 phase AC from the DC Link for 
TM2 power when combined with Inverter 21 power. 
PAYLD Payload
PC_CAL Indicates a Pedal calibration is in process when the text is highlighted. 
PC_HP Indicates the retard pedal requires calibration when the text is highlighted. 
PC_RET Indicates the retard pedal requires calibration when the text is highlighted. 
Table 4. Glossary of Terms (Continued)
Term Description
Wabtec Proprietary and Confidential Information 53
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
PCCALOK Indicates DSC pedal calibration has been completed successfully when the text is highlighted. 
PHB Primary H-Bridge
POTREF The Pot Reference voltage level established by the Control System that supplies Accel Pedal and 
Retard Pedal. The Pot Ref voltage is displayed. 
PRKBRKFB Indicates the current status of the Park Brake feedback. Park brake is ON when the text is high-
lighted. 
PRKBRKOFF Indicates the park brake is commanded OFF when the text is highlighted. 
PRKBRKSW Indicates the Operator Cab park brake switch has been activated when the text is highlighted. 
PROPEL Indicates the Control System is in the Propel Mode when the text is listed or highlighted. 
PROPINH Propel Inhibit restriction
PROPLO Propulsion Lock Out ON indication when the is highlighted. 
PROPT Indicates the calculated PSC temperature in degrees C and displayed. 
PS Power Supply which provides +5 VDC, ±15 VDC, ±24 VDC regulated voltage. 
PSC Propulsion System Controller is one of the CPU cards. 
PSCVER Indicates the GE software version loaded and displayed. 
PSCLINK Indicates the DC link status in text. 
PSCMODE Indicates the mode the PSC system is currently set for (Propel, Retard, Rest, etc.) in text. 
PS-UN Power Supply unregulated.
PSOK Indicates the Power Supply (PS) status is OK when the text is highlighted. 
PTEMP Indicates the calculated PSC temperature in degrees C displayed. 
PTU or wPTU Portable Test Unit (PTU) loaded with GE OHV Toolbox software (wPTU). 
PWR1 & PWR2 Power feedback from Inverter 1 and Inverter 2. 
R1 Resistor 1 (R1) is used in the battery boost circuit to current limit battery power to the alternator 
excitation field. 
RD Rectifier Diode (RD) panel, if equipped, used to convert traction Alternator 3 phase output to DC 
for the DC Link. 
RDA, RDB, & 
RDC 
Rectifier Diode modules (RDA, B, & C) module, if equipped, used to convert traction Alternator 3 
phase output to DC for the DC Link. 
READY Indicates the Control System is ready for truck operation when the text is displayed or highlighted. 
RESET or 
RESET-DO 
Indicates the reset/dump body up override push button has been activated when the text is high-
lighted. 
REST Indicates the Control System is in the Rest Mode when the text is displayed or highlighted. 
RESTREQ Indicates a Rest Mode has been requested when the text is highlighted. 
RESTSW Indicates the Rest Switch in the Operator Cab has been activated when the text is highlighted. 
RETARD Indicates the Control System is in the Retard Mode when the text is displayed or highlighted. 
RETRD-SEL Indicates the retard pedal request state when the text is highlighted. 
RETSPD Displays the RSC pot setting in MPH or KPH in text . 
REVERSE Indicates the Control System is commanding the reverse direction in the Propel Mode when the 
text is highlighted. 
Table 4. Glossary of Terms (Continued)
Term Description
54 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
REVIN Indicates the propulsion system of the truck is in reverse direction when the text is highlighted. 
REVREQ Indicates the operator has selected Reverse when the text is highlighted. 
REVT Truck is moving in reverse regardless of direction request.
RFRPM Indicates the truck right front wheel speed displayed in text. 
RG1A - RG5C Grid Resistors dissipate power from the DC link during retarding, self-load, and Inverter Filter 
Capacitor discharge operations. Fewer or more grid resistors may be used in specific GE systems 
or specific applications. 
RGBM1, RGBM2 Capacitor discharge resistors used to discharge Blower Motor Capacitors (CGBM1 & CGBM2) after 
system shut down. 
RSC Indicates the Retard Speed Control system is active when the text is highlighted. 
RSCSPD Indicates the RSC pot setting when RSC is active displayed in text . 
RTRDCONT Indicates only Continuous Retard effort is available in the Retard Mode when the text is high-
lighted. 
RWSPEED Displays the right rear wheel speed (based on the Speed Sensor). Refer to SS1, SS2, SS3, & SS4. 
SCACTIVE Speed control is active when the text is highlighted. 
SCR3 SCR3 commands, part of alternator boost circuit.
SELFLOAD Indicates the Control System is in the Self-load Mode when the text is displayed or highlighted. 
SHB Secondary H-Bridge
SPD-V Cruise lever voltage or RSC pot voltage.
SPD1 or SPD2 Indicates OEM option Speed 1 setting or Speed 2 setting is active when the text is highlighted. 
SPDLIM or 
SPLIM 
A condition exists preventing full truck speed and an Event Code has been logged when the text is 
displayed or highlighted. Refer to the Event Codes listing for condition. 
SPDLIMIT Indicates the maximum speed setting displayed in text. 
SPDOVRID Indicates the Speed Override function is active and preventing propulsion to greater speed when 
the text is highlighted. 
SS1, SS2, SS3, & 
SS4 
Speed Sensors mounted on the rear truck wheels(SS1 & SS2) and on the front truck wheels (SS3 & 
SS4). 
SUBSTATE Indicates the test state machine state displayed. 
SUPSDWN Indicates a Start Up/Shut Down Mode is active when the text is highlighted. 
SYSEVENT Indicates a non-restrictive System Event has occurred as described by the Event Codes. The oper-
ation of the Control System is unaffected. Refer to the Event Codes listing for System Event. 
SYSRUN System RUN signal to engine.
TCI Truck Control Interface is a CPU card in the ICP panel. 
TEST Indicates Test Mode is active when the text is highlighted. 
TH1 Alternator Field Thyrite (Varistor) protects the Alternator field circuit from voltage transients. 
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. 
Table 4. Glossary of Terms (Continued)
Term Description
Wabtec Proprietary and Confidential Information 55
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
TQCMD1 & 
TQCMD2 
Indicates the torque command to Inverter 1 and Inverter 2 displayed in text. 
TRQFB1 & 
TRQFB2 
Indicates the torque feedback for Inverter 1 and Inverter 2 displayed in text. 
TRUCKSPD Displays the truck speed in MPH or KPH . 
VAM1, VAM2, 
VAM3, VAM4, 
VAM5 
Voltage Attenuation Modules isolates and reduce voltage levels of systems components for feed-
back into system controllers. Refer to electrical schematics for VAM assignments. 
VID Vehicle Information Display
WARM_UP Indicates an Engine Warm Up Mode request when the text is highlighted. 
WHEELLOCK Wheel Lock signal.
WSLIDE1 & 
WSLIDE2 
Indicates Wheel 1 or Wheel 2 is sliding during Retard effort when the text is highlighted. 
WSPIN1 & 
WSPIN2 
Indicates Wheel 1 or Wheel 2 is spinning during Propulsion effort when the text is highlighted. 
WTB Wheel and Transformer Cooling Blower
UI User Interface
HMI Human Machine Interface
Table 4. Glossary of Terms (Continued)
Term Description
56 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
A. PRE-POWER UP CHECKS
TRUCK Number ____________________ Date ____________________
A-1 Cabling
The 17KG551 is common for both the 250 ton and 320 ton vehicles. The sign off sheet (Table 5) includes components
for both vehicles and the user should mark NA for equipment not installed on the truck. Complete the sign off for
each device.
For components that come prewired like the retarding grids, the destination terminal only needs to be verified.
 
Table 5. Cabling Sign Off Sheet
Name
Origin
Device
Origin
Terminal
Destination
Device
Destination
Terminal
Verified
Alternator 5GTA51
T101 T1 APL
ALT
T1
T201 T2 APL T2
T301 T3 APL T3
T19 T19 APL T19
T20 T20 APL T20
F1 F1 APL F1
F2 F2 APL F2
Wheel Motor 5GEB36
TA1 TM1A BUS
TM1
TA
TB1 TM1B BUS TB
TC1 TM1C BUS TC
TA2 TM2A BUS
TM2
TA
TB2 TM2B BUS TB
TC2 TM2C BUS TC
Wheel Motor 5GDY106B
TA1 TM1A BUS
TM1
TA
TB1 TM1B BUS TB
TC1 TM1C BUS TC
TA2 TM2A BUS
TM2
TA
TB2 TM2B BUS TB
TC2 TM2C BUS TC
Retarding Grid 17EM160
4DCP6 GRD BUS RG1A B
5DCP6 GRD BUS RG3A B
6DCP6 GRD BUS RG4A B
Wabtec Proprietary and Confidential Information 57
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
7DCP6 GRD BUS RG2A B
CVBA5 CVBA APL RG1C A
CVBB5 CVBB APL RG3C A
CVBC5 CVBC APL RG2C A
CVBD5 CVBD APL RG4C A
GMB11
GI1
T1
GB1
A
GMB12 T2 B
GMB13 T3 C
GMB1G4
GND9B
BLK
GNDGMB1G5
GMB1G6
GMB21
GI2
T1
GB2
A
GMB22 T2 B
GMB23 T3 C
GMB2G4
GND9A
BLK
GNDGMB2G5
GMB2G6
Retarding Grid 17EM164
4DCP6 GRD BUS RG1E B
5DCP6 GRD BUS RG3A B
6DCP6 GRD BUS RG4E B
7DCP6 GRD BUS RG2A B
CVBA5 CVBA APL RG1A B
CVBB5 CVBB APL RG3E A
CVBC5 CVBC APL RG2E A
CVBD5 CVBD APL RG4A A
GMB11
GI1
T1
GBM1
A
GMB12 T2 B
GMB13 T3 C
GMB1G4
GND9B BLK GNDGMB1G5
GMB1G6
Table 5. Cabling Sign Off Sheet
Name
Origin
Device
Origin
Terminal
Destination
Device
Destination
Terminal
Verified
58 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
GMB21
GI2
T1
GBM2
A
GMB22 T2 B
GMB23 T3 C
GMB2G4
GND9A BLK GNDGMB2G5
GMB2G6
OEM Battery Connection
BATP1 BATFU 1 BATTSW M
RTN1 RTN BUS BATTERY -
Control Group 5GDY126
CGB1
CI1
T1
CGB
A
CGB2 T2 B
CGB3 T3 C
CGBG4
GND9D BLK GNDCGBG5
CGBG6
WM Blower 5GDY126
WMB1
CI2
T1
WTB
A
WMB2 T2 B
WMB3 T3 C
WMBG4
GND9C BLK GNDWMBG5
WMBG6
Secondary Link 17ET38
PBP5 PBA APL SLT H1
PBN5 PBB APL SLT H2
SBP9 SBA APL SLT X1
SBN9 SBB APL SLT X2
System Grounding - Control Group, Retarding Grid Box, and Secondary Link Transformer Truck Grounding
KGGND GND6 BLK
TKGND BLKRGBGND GNDGB BLK
SLTGND GNDXF BLK
Table 5. Cabling Sign Off Sheet
Name
Origin
Device
Origin
Terminal
Destination
Device
Destination
Terminal
Verified
Wabtec Proprietary and Confidential Information 59
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
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60 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
A-2 Power Supply Checks
Table 6. Power Supply Checks
Truck Function Name
Input
Output
Notes Verified
Power Supply to ground checks 
CPD TPCR1 Greater than 100 ohms
CPD TP+15 Greater than 100 ohms
CPD TP-15 Greater than 100 ohms
CPD TP+5 Greater than 100 ohms
Speed Sensor SS1 +15V Greater than 100 ohms at 
OEM Connection reference 
Left Rear Wheel 15LRW
Speed Sensor SS2 +15V Greater than 100 ohms at 
OEM Connection reference 
Right Rear Wheel 15RRW
Speed Sensor SS3 +15V Greater than 100 ohms at 
OEM Connection reference 
Left Front 15LWFS
Speed Sensor SS4 +15V Greater than 100 ohms at 
OEM Connection reference 
Right Front 15RWFS
CPS Switch Set CPS switch to off
Physical Checks
Alternator Physical - Ship-
ping material
Verify that VCI shipping 
paper, decadent, and plas-
tic are removed 
Alternator Physical - 
Brushes
Verify all brushes are 
seated
Alternator Physical - Cables Verify F1, F2, T19, T20, 
Speed sensor cables are 
installed and secured
Alternator Physical - Covers Verify covers are properly 
latched and secured
Equipment Mounting Per OEM requirements
CGB Ground Typically less than 1 ohm
WTB Ground Typically less than 1 ohm
Blowers Inlet, outlet, ducting area 
free from debris including 
Alternator, Grid box, Axle 
box, Control group cooling 
blower, and wheel motor 
cooling blower
Wabtec Proprietary and Confidential Information 61
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Speed sensor lock wires 
installed
Control Group Blower, 
Wheel motor cooling 
blower, wheel motors
General Inspection Remove dirt, dust, debris
Moisture No Moisture present
Table 6. Power Supply Checks
Truck Function Name
Input
Output
Notes Verified
62 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
B. TRUCK INITIAL CHECKOUT
TRUCK Number ____________________ Date ____________________
 
Table 7. Truck Initial Checkout
Truck Function Name
Input
Output
Notes Verified
LOW VOLTAGE POWER SUPPLY CHECKS 17FH47
Backfeeds CPD lights not illuminated
LEDs (+15V, –15V, +5V, +24V, 
–24V)
Illuminated Green
CPD TP +5V Typical is 5.1 VDC
CPD TP +15V Typical is 15.1 VDC
CPD TP -15V Typical is -15.1 VDC
CPD TPPR POT Reference Typical is 12.6 VDC
Power Distribution Fuses, 
Speed Sensor Fuses FL489 
Panel
Lights illuminated 
Software Versions
DSC Update SW to current tar-
get, document revision
Inverters TMC1, TMC2, DAB Update SW to current tar-
get, document revision
Inverters CB1, CB2, GB1, 
GB2
Update SW to current tar-
get, document revision
VID Update SW to current tar-
get, document revision
DSC CPU Setup and Config
Setup DSC
Config DSC
CAN CommunicationEngine CAN – J1939 DSC-CAN1 Verify messages being 
received
Komatsu RPC DSC-CAN2 Verify messages being 
received
OEM (3rd Party) DSC-CAN3 If 3rd Party Devices Present
Verify messages being 
received
Ethernet Communication
OEM Ethernet DSC-EN2 Verify communication from 
personal PC to GE from Cab
Wabtec Proprietary and Confidential Information 63
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
VID Ethernet DSC-EN4 Verify Screens are being 
displayed
Inv01 TMC1 Verify Tics are moving
Inv02 TMC2 Verify Tics are moving
Inv03 DAB Verify Tics are moving
Inv04 CGB Verify Tics are moving
Inv05 WTB Verify Tics are moving
Inv06 GBR1 Verify Tics are moving
Inv07 GBR2 Verify Tics are moving
Truck Settings
Set Truck ID
Set Time
Pedal Cal
Validate no active events
Truck OEM Input and Output Checkout
Display Test
Body Up
Propulsion System Not 
Ready
No DC Link Voltage
Engine Warm Up
No Propel
Retard
Traction Control
Temperature (Analog)
Speedometer (Analog)
Digital Inputs
Traction Motor Pressure 
Switch
DSC-DI07 +24V = Air Pressure Present
Keyswitch DSC-DI02 +24V When Keyswitch is 
Picked Up
Parking Brake DSC-DI10 = Parking Brake Released
Dump Body DSC-DI12 +24V = Dump Body Down
Propel Lockout DSC-DI13 0V = Propel is Locked Out
Table 7. Truck Initial Checkout
Truck Function Name
Input
Output
Notes Verified
64 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Rest Mode DSC-DI20 Use Propel Lockout to verify 
rest mode goes high when 
in Lockout
+24V = Rest Mode 
requested 
Forward Direction Input DSC-DI15 +24V = Forward Direction 
Requested
Reverse Direction Input DSC-DI16 +24V = Reverse Direction 
Requested
Data Store DSC-DI17 +24V = Data Store 
Requested
Cruise Control DSC-DI18 +24V = Cruise Control On
Weak Reset / Dump Body 
Override
DSC-DI19 +24V = Reset / Dump Body 
Override
Wheel Spin / Slide Disable DSC-DI22 +24V = Wheel Spin / Slide 
disabled
Brake Test DSC-DI24 +24V = Brake Test 
requested
Analog Inputs
Acceleration Pedal DSC-AI04 FULL OFF - typical is 1.6 
VDC
 FULL ON - typical is 8.5 
VDC
Retard Pedal DSC-AI15 FULL OFF - typical is 1.25 
VDC 
FULL ON - typical is 8.0 VDC
Cruise Control DSC-AI31 No switch activated – typi-
cal is 14.7 VDC
Set – typical is 9.77 VDC
Cancel – typical is 4.39 VDC
Speed (-) - typical is 2.48 
VDC
Speed (+) – typical is 0.95 
VDC 
Temperature Inputs
Transformer Temperature 
#1
DAB-
TEMP1
1000 Ω = 0 degrees C
Display value is in Degrees, 
should be ambient when 
cool
Transformer Temperature 
#2
DAB-
TEMP2
1000 Ω = 0 degrees C
Display value is in Degrees, 
should be ambient when 
cool
Digital Outputs using console command, iotest
Table 7. Truck Initial Checkout
Truck Function Name
Input
Output
Notes Verified
Wabtec Proprietary and Confidential Information 65
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
External Retard Light DSC-DO07 True = Light On
Forward DSC-DO19 True = Forward 
Reverse DSC-DO20 True = Reverse
System Run DSC-DO23 True = System Run
 Brake Test 
System Light
DSC-DO24 True = Light On
System Busy Light at OEM 
Isolation Station
DSC-
DO10B
True = Light On
Resistance Checks
Main Power Circuit 1 Meg Ohm minimum, 
Record Results
Alt Field/Tertiary 1 Meg Ohm minimum, 
Record Results
Restore Remove jumpers and 
restore circuitry
Secondary H-Bridge Ohm check winding(s) 
phase to phase, measure 
ohms to ground and verify 
> 1k ohm
CBI CGB T1 Ohm check winding(s) 
phase to phase, measure 
ohms to ground and verify 
> 1k ohm
CBI WTB T1 Ohm check winding(s) 
phase to phase, measure 
ohms to ground and verify 
> 1k ohm
CBI GBR1 T1 Ohm check winding(s) 
phase to phase, measure 
ohms to ground and verify 
> 1k ohm
CBI GBR2 T1 Ohm check winding(s) 
phase to phase, measure 
ohms to ground and verify 
> 1k ohm
Primary H-Bridge Ohm check winding(s) 
phase to phase, measure 
ohms to ground and verify 
> 1k ohm
Table 7. Truck Initial Checkout
Truck Function Name
Input
Output
Notes Verified
66 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
C. ENGINE RUNNING TESTS
TRUCK Number ____________________ Date ____________________
 
Table 8. Engine Running Tests
Truck Function Name
Input
Output
Notes Verified
Initial Checks
GF Cutout Cut Out Position
Doors and Covers Properly Installed
Traction Motors Inverter 
Cut Out
If WMs not installed, note 
will have 2 persistent 
events
Wheel Motor Cables If WMs not Installed, verify 
power cable terminals in 
axle box are insulated via 
3” air gap from each other 
and to ground or insulating 
boots installed
Truck OEM Engine Check-
out
Complete checkout
Battery Boost
CCL1, CCL2, CCL3, CCL4 All LEDs illuminate
Battery Boost Transitions to 18 V DC and 
then 0 V DC
VI Test
Events Zero Events or only known 
events
WM Cooling Blower Proper airflow, direction 
Control Group Cooling 
Blower
Proper airflow, direction
Grid Blower 1 Proper airflow, direction
Grid Blower 2 Proper airflow, direction
Capacitance Test
Complete Capacitance Test Zero Events or only known 
events
Loss of J1939 Communication
Disconnect J1939 Verify Event #49 is active
Accelerator pedal not 
depressed
Idle
Accelerator pedal mid posi-
tion
1180 RPM
Wabtec Proprietary and Confidential Information 67
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Accelerator pedal fully 
depressed
1930 RPM
Reconnect J1939 Zero Events or only known 
events
Direction Control Lever (Wheels Installed)
Forward Verify torque command 
and feedback
Reverse Verify torque command 
and feedback
Zero Events or only known 
events
Engine Warning
Engine Warning Event 619
NOPROP Active
Blower Test Verify Blower Test Passes
Blower Test
Blower Test Verify Blower Test Passes
Axle Box Pressure Switch DSC-DI07 Picked up WM Cooling 
blower above 2100 RPM 
and dropped out below 50 
RPM.
Loadbox
Slow Ramp Of accel Pedal 
to full pedal
Verify no events occur and 
HP Alt In meets Truck OEM 
Criteria 
Snap ThrottAle Accelerator 
Pedal from 0 to full pedal
Hold 2 minutes to get 
steady state data and 
record AP Alt In
Engine Warm Verify Engine Warm
Data Dump Save “Quick” 
Vibration Measurements 
Horizontal 725 RPM Record velocity (in/s)
Horizontal 800 RPM Record velocity (in/s)
Horizontal 1000 rpm Record velocity (in/s)
Horizontal 1700 rpm Record velocity (in/s)
Horizontal 1830 rpm Record velocity (in/s)
Vertical 725 RPM Record velocity (in/s)
Vertical l 800 RPM Record velocity (in/s)
Table 8. Engine Running Tests
Truck Function Name
Input
Output
Notes Verified
68 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
Vertical 1000 rpm Record velocity (in/s)
Vertical 1700 rpm Record velocity (in/s)
Vertical 1830 rpm Record velocity (in/s)
Axial 725 RPM Record velocity (in/s)
Axial 800 RPM Record velocity (in/s)
Axial 1000 rpm Record velocity (in/s)
Axial 1700 rpm Record velocity (in/s)
Axial 1830 rpm Record velocity (in/s)
Table 8. Engine Running Tests
Truck Function Name
Input
Output
Notes Verified
Wabtec Proprietary and Confidential Information 69
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
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70 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
D. KEY SERIAL NUMBERS
TRUCK Number ____________________ Date ____________________
Tracking serial numbers of key components over the life of a truck and the history of changes to components is an
essential component of maintenance history. The below list reflects the key serial numbers that should be tracked
over the life of the truck. Note, for the control group parts the “:CA_: “is the location of the part as shown within the
GE schematic.
 
Table 9. Key Serial Numbers
Device And Location Part Number Serial NumberDate
250 T 5GEB36: TM1
250 T 5GEB36: TM2
320 T 5GDY106B: TM1
320 T 5GDY106B: TM2
17ET38
250 T 17EM160
320 T 17EM164
5GDY126: CGB
5GDY126: WTB
5GTA51
17KG551
17KG551:CA1:17FL489
17KG551:CA1:DSC1: FODC1
17KG551:CA1:DSC2: FODC2
17KG551:CA1:DSC3: TMC
17KG551:CA1:DSC4: TMC
17KG551:CA1:DSC5: DAB
17KG551:CA1:DSC6: ANALG
17KG551:CA1:DSC7: I/O
17KG551:CA1:DSC8: I/O
17KG551:CA1:DSC9: ETH
17KG551:CA1:DSC10: CPU
17KG551:CA1:GDP
17KG551:CA1:PS
17KG551:CA1:PC
17KG551:CA4:P1A+
17KG551:CA4:P1A-
17KG551:CA4:P1B+
17KG551:CA4:P1B-
Wabtec Proprietary and Confidential Information 71
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
17KG551:CA4:P1C+
17KG551:CA4:P1C-
17KG551:CA5:P2A+
17KG551:CA5:P2A-
17KG551:CA5:P2B+
17KG551:CA5:P2B-
17KG551:CA5:P2C+
17KG551:CA5:P2C-
17KG551:CA5:CM1
17KG551:CA5:CM2
17KG551:CA5:CM3
17KG551:CA5:CM4
17KG551:CA5:PB1
17KG551:CA5:PB2
17KG551:CA2:RD
17KG551:CA2:AFSE
17KG551:CA9:GI2
17KG551:CA9:GI1
17KG551:CA9:CI2
17KG551:CA9:CI1
17KG551:CA9:SB
17KG551:CA9:ES1
Table 9. Key Serial Numbers
Device And Location Part Number Serial Number Date
72 Wabtec Proprietary and Confidential Information
GEK-91843B
Vehicle Test Instructions for OHV 17KG551 Control Group
E. FUNCTIONS
A Function gives the user information about the operating system, or allows the user to change one of the adjust-
able settings of the operating system. In this section the individual Functions are given a brief description and a table
as an overview of what the function is used for, and how the operator can access the Function, using the various
human machine interface (HMI) devices. 
For further information on all the Functions available see, GEK-91842, HUMAN MACHINE INTERFACE (HMI) MANUAL.
E-1 PEDAL CALIBRATION
The OEM supplied accelerator pedal, retard pedal, and retard lever must be calibrated for proper truck operation. 
For further information on Pedal Calibration Function see, GEK-91842, HUMAN MACHINE INTERFACE (HMI) MANUAL.
E-2 TRUCK ID
Enter Truck ID based on OEM or Mine numbering system. Note, Truck ID must be entered after software updates 
and on DSC controller change. Note, no alpha characters are allowed so if mine truck number is MT301 then user 
would enter 301.
For further information on Truck ID Function see, GEK-91842, HUMAN MACHINE INTERFACE (HMI) MANUAL.
E-3 TIME DATE
Enter Time and Date. Time and Date must be verified after software updates. 
Table 10. Pedal Calibration Availability
UI Path or Command Notes
VID Settings\Pedal Cal Initiate and Display
WebPTU Config\Pedal Calibraton Initiate and Display
Console none
DID Menu\Truck Conf\Pedal 
Calib
Initiate
Table 11. Truck ID Availability
UI Path or Command Notes
VID Settings\TRUCK ID Change and Display
WebPTU Setup\config
Console none
DID Menu\Truck Conf\Truck ID Change and Display
Table 12. Time Date Availability
UI Path or Command Notes
VID Settings\Set time Change and Display
WebPTU Config\set time
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Vehicle Test Instructions for OHV 17KG551 Control Group
For further information on Truck Date and Time Function see, GEK-91842, HUMAN MACHINE INTERFACE (HMI) MAN-
UAL.
E-4 SETUP DSC
Setup needs to be completed during truck build at OEM Factory, during truck commissioning, or whenever a new
DSC CPU is inserted into an existing truck. After updating the DSC CPU Software setup may need to be performed
and the user will be notified in this unique circumstance with event 24-9 (psc/dsc) or 632-9(tci) will log "config Setup
- Old version" "please re-run 'setup'."
 
For further information on Setup DSC Function see, GEK-91842, HUMAN MACHINE INTERFACE (HMI) MANUAL.
E-5 CONFIGURATION OF DSC
After the card has been properly setup, the user can then choose to modify mine specific configuration options. This
is like using the wPTU Toolbox’s configuration utility which allowed the user to set things such as mine specific speed
limits for a FB174 card. Anytime “setup” is run, the existing configuration options are removed and must be re-set by
the user.
 
For further information on Configuration of DSC Function see, GEK-91842, HUMAN MACHINE INTERFACE (HMI) MAN-
UAL.
Console none
DID Menu\Truck Conf\Time 
Date
Change and Display
Table 13. Availability
UI Path or Command Notes
VID None
WebPTU setup\login
setup\initial setup
Console setup
DID none
Table 14. Inverter Cut Out Availability
UI Path or Command Notes
VID None
WebPTU Setup\login
Setup\Config
Console config
DID none
Table 12. Time Date Availability (Continued)
UI Path or Command Notes
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Vehicle Test Instructions for OHV 17KG551 Control Group
E-6 CAPACITANCE TEST
The user can initiate a capacitance test that will measure the traction link capacitance and if equipped, the second-
ary link capacitance. The capacitance test also verifies the discharge network. Events 70, 71, 72 may be generated
during the cap test.
For further information on Capacitance Test Function see, GEK-91842, HUMAN MACHINE INTERFACE (HMI) MAN-
UAL.
E-7 DISPLAY TEST
The display test is used to change state of CAN based Booleans and analogs that are sent from the DSC to OEM con-
troller to verify proper display on OEM Electronic Display Panel (EDP). The speed test that was included in the DID
menu is located on the Display Test Screen. Speed test historically was used to calibrate analog RPM gauge. 
For further information on Display Test Function see, GEK-91842, HUMAN MACHINE INTERFACE (HMI) MANUAL.
E-8 LOADBOX
Loadbox is a test that can be used to verify engine HP, alternator operation, and grid components including blowers,
choppers, contactors. OEM parasitic loads like the radiator fan should be forced to an on state to improve consis-
tency in benchmarking the engine. During Loadbox the control loads the engine via the alternator whose output is
directed into the grid box where the power is dissipated as heat.
Table 15. Capacitance Test Availability
UI Path or Command Notes
VID Tests\Capacitance Display and Test
WebPTU Tests\Capacitance Test Display and Test
Console Cap Display
DID Menu\Test menu\Cap Test Display and Test
Table 16. Display Test Availability
UI Path or Command Notes
VID Tests\Display Test Display and Test
WebPTU None
Console Imtest Booleans only
DID Menu\Test Menu\Speed-
ometer
Speedometer Analog Only
Table 17. Loadbox Availability
UI Path Options
VID Test\Loadbox Display and Test
WebPTU Tests\Self Load Display and Test
Console Loadbox\Self Load Display
DID Menu\Test Menu\Loadbox Display and Test
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Vehicle Test Instructions for OHV 17KG551 Control Group
For further information on Loadbox Function see, GEK-91842, HUMAN MACHINE INTERFACE (HMI) MANUAL.
E-9 BLOWER TEST
Control groups equipped with electrification have a test to verify blower operation. Blower test ramps each blower to
100% call and verifies speed and expected HP. The test will indicate if the individual blower passed or failed. and if
the system pass or failed. The call speed is based on altitude and temperature. 
For further information on Blower Test Function see, GEK-91842, HUMAN MACHINE INTERFACE (HMI) MANUAL.
E-10 DATA CAPTURE
Data Capture is the process of copying data from the control to a USB thumb drive that is either plugged into the VID
or to the DSC. Data Capture can be initiated while the truck is moving or while parked. The transfer rate is faster
when the truck is parked.
Table 18. Blower Test Availability
UI Path or Command Notes
VID Tests\Blower Test Display and initiate
WebPTU Tests\Blower Test Display and initiate
Console None
DID None
Table 19. Data Capture Availability
UI Path or Command Notes
VID System\Data Files
WebPTU Tests\Download vehicle 
data
Using this method will 
transfer the files directly to 
the browser as a tar file. 
The tar file can be found in 
the standard downloaddirectory for the browser.
Console Download xx xx = quick, all, GE. Note, 
these are case sensitive.
DID Menu\Data Menu\Dump 
Data
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Vehicle Test Instructions for OHV 17KG551 Control Group
For further information on Data Capture Function see, GEK-91842, HUMAN MACHINE INTERFACE (HMI) MANUAL.
E-11 SOFTWARE VERSIONS
OEMs, Service shops, and customers should manage Software Versions on a vehicle, on a fleet of vehicles, and
across multiple properties. Target software versions should be published and the target software should be installed
on each vehicle. For updates to a target software revision a systematic plan to roll out new releases to each vehicle
should be developed. A review of new software releases versus current target software should be done on a bi-
annual basis. The currently installed drive system software versions can be found on the following UI: 
 
For further information on Software Versions Function see, GEK-91842, HUMAN MACHINE INTERFACE (HMI) MAN-
UAL.
E-12 CAN COMMUNICATION
The Invertex II and IIe control system can communicate on up to 3 CAN buses. The OEM is responsible for the CAN
Backbone, including network termination resistors. The GE system is a “stub” off of the OEM networks. The OEM is
responsible for approving and qualifying the addition of any devices onto the CAN network.
• DSC-CAN1 The Engine J1939 network enables the sharing of data between the Engine and Drive System.
• DSC-CAN2 The OEM RPC network enables the sharing of data between key truck subsystems 
• DSC-CAN3 3rd Party CAN Network enables the sharing of data between the OEM or 3rd party device and the GE
Drive System.
DSC CPU Jumper the ground and 
download pins.
- All four STATUS LED’s sol-
idly illuminated – Download 
pins being jumpered
- One RED LED flashing Red 
light – File Copy in process
- STATUS 1 GREEN LED 
Flashing – Copy process 
complete – okay to remove
Flash drive
- Normal (STATUS 2, 3 & 4 
RED LED’s cycling, STATUS 1 
GREEN LED solidly
illuminated)
Table 20. Software Versions Availability
UI Path or Command Notes
VID System\Versions Display
WebPTU Config\SW/HW Info Display 
Console Ver, Verinv Display
DID Info Menu\SW Version Display
Table 19. Data Capture Availability
UI Path or Command Notes
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Vehicle Test Instructions for OHV 17KG551 Control Group
 
For further information on CAN Communication Function see, GEK-91842, HUMAN MACHINE INTERFACE (HMI) MAN-
UAL.
E-13 ETHERNET COMMUNICATION
Multiple ethernet networks may exist on an OEM truck with multiple devices on each network. Consult the drive sys-
tem schematic to determine the ethernet network configuration for a specific truck. The following are ethernet net-
works that may be available:
• DSC-ETHERNET2 OEM Interface for communication to DSC. The OEM may run this network directly to the cab
or the network may be part of an OEM designed network. Consult OEM documentation for IP Addressing and
availability of DHCP services. The Ethernet will have a baud rate of 10/100Mb
• DSC-ETHERNET4 Vehicle Information Display (VID) Panel Interface
• DSC Inverters and CPU network
 
For further information on Ethernet Communication Function see, GEK-91842, HUMAN MACHINE INTERFACE (HMI)
MANUAL.
E-14 I/O MONITORING
The current value of the hardwired inputs and outputs can be viewed in several locations within the UI. For testing,
the console can be used to force digital outputs while the engine is not running.
 
Table 21. Communications Monitoring (CAN) Availability
UI Path or Command Notes
VID Data\Comms\CAN Devices Display
WebPTU Realtime\Comm Status Display 
Console can Display
DID Display
Table 22. Communication Monitoring Ethernet Availability
UI Path or Command Notes
VID Data\Comms\Ethernet
Data\Comms\Inverter Sta-
tus
Display
WebPTU Realtime\Comm Status Display 
Console network Display
DID Display
Table 23. Hardwired Digital And Analog I/O Monitoring Availability
UI Path or Command Notes
VID Data\Real Time\Analogs
Data\Real Time \Inputs
Data\Real Time \Temps
Display
WebPTU Realtime\Real Time Temps 
Realtime\IO
Display 
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Vehicle Test Instructions for OHV 17KG551 Control Group
For further information on I\O Monitoring Function see, GEK-91842, HUMAN MACHINE INTERFACE (HMI) MANUAL.
Console di, ditest, ai, ao, io, iotest Display and Change
DID NA Display
Table 23. Hardwired Digital And Analog I/O Monitoring Availability
UI Path or Command Notes
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80 Wabtec Proprietary and Confidential Information
	1. GENERAL INFORMATION
	1.1. INTRODUCTION
	1.2. RELATED PUBLICATIONS
	1.3. SAFETY INFORMATION
	1.4. CAPACITOR DISCHARGE PROCEDURE
	2. TOOLS, TEST EQUIPMENT, AND HANDLING ELECTRONIC COMPONENTS
	2.1. TOOLS AND TEST EQUIPMENT
	2.2. HANDLING ELECTRONIC PANEL PRINTED CIRCUIT CARDS
	3. PRE-POWER UP CHECKS
	3.1. WIRING CHECKS
	3.2. CONFIGURATION MANAGEMENT
	3.3. GENERAL CLEAN-UP AND INSPECTION
	4. TRUCK INITIAL CHECKOUT
	4.1. LOW VOLTAGE POWER SUPPLY CHECKS
	4.2. VERIFY GE DRIVE SYSTEM SOFTWARE REVISIONS
	4.3. SETUP AND CONFIG DSC
	4.4. CIRCUIT CONTINUITY, RESISTANCE CHECKS, AND ADJUSTMENTS
	4.5. MEGGER TEST FOR GROUNDS
	5. ENGINE RUNNING CHECKS
	5.1. INITIAL CHECKS
	5.2. BATTERY BOOST CIRCUIT VERIFICATION
	5.3. VI TEST
	5.4. CAPACITANCE TEST
	5.5. DIRECTIONAL CONTROL LEVER
	5.6. LOSS OF J1939 COMMUNICATION
	5.7. ENGINE WARNING (RED LIGHT)
	5.8. BLOWER TEST AND AXLE BOX PRESSURE SWITCH
	5.9. SELF LOAD (LOADBOX) TEST PROCEDURE
	5.10. POWER MODULE VIBRATION MEASUREMENTS
	6. GLOSSARY OF TERMS, ACRONYMS, AND ABBREVIATIONS