GE IC3645SP4U400N3 manuals

74 pages820.3 Kb

4Section 1. INTRODUCTION
- 8=Look ahead =Look again =Automatic look again and reset
- =The control monitors both armature and field FET's at
- =The control will not allow the line contactor to close at
- 9=Displays 100 to 0 percent charge. =Display blinks with 20% charge. Disables pump circuit
- =Monitor existing system status codes for both traction
- =Monitor battery state of charge, if available. =Monitor hourmeter reading on traction and pump
- 10=Three speeds, adjustable from O to 100% motor
11Section 3.0 ORDERING INFORMATION, ELEMENTARY AND OUTLINE DRAWINGS
- 13OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS
- Section 3.3 Traction Elementary
  - FORWARD SW.
  - START SW.
  - SEAT SW.
  - FIELD
  - ARMATURE
  - REVERSE SW.
- OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS
- Section 3.4 Pump Elementary
  - TO TRACTION
  - SX-2
  - CONTROL PLUG PL2
- 14***
  - PL2-10
16 January 2000
Section 4.0 TROUBLESHOOTING AND DIAGNOSTIC STATUS CODES
- The following Dos and Donts should be observed
- - 17=Digital tachometers and resolvers =Dash display cabling =RS-232 cabling
  - =Analog and digital signals greater than 15 V DC and
  - =DC switching signals greater than 15 V =Signals with currents greater than 250 mA and less than
  - =DC busses less than 10 A =Contactor coils less than 10 A =Machine fields less than 10 A
  - =Motor armature loops =DC outputs 10 A and above =Motor field loops 10 A and above
  - =All cables and wires of like signal levels and power
  - =In general, different levels must run in separate wire
  - =Interconnecting wire runs should carry a level
  - =If wires are the same level and same type signal, group
  - =When unlike signals must cross, cross them in 90
- 18Pow-R-
- WasH
  - Nye Nye NyeNye
20NONE Segments do not illuminate on the
-01 No seat switch or deadman switch
- TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
- initial power up. This status code will be displayed when P4 is greater
- initial power up. This status code will be displayed when P5 is greater
21-02 Forward directional switch is closed on
- than 60% of battery voltage at initial key switch on.
-03 Reverse directional switch is closed on
- TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
- than 60% of battery voltage at initial key switch on.
22-05 Start switch fails to close. This status code will be displayed when P7 is less
-06 Accelerator depressed with no
23-07 Accelerator input voltage too high on
-08 Accelerator input voltage too low on
24-09 Both the forward and reverse
-10 Steer angle potentiometer voltage is
25-11 Start switch closed on power up after
-12 Steer angle potentiometer voltage is
- TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
- card is mis-adjusted. This status code will be displayed when the battery
26-15 Battery voltage is too low or control
- volts are less than 1.95 volts per cell at initial key switch on. See table below.
-16 Battery voltage is too high or control
- TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
- volts are greater than 2.4 volts per cell at initial key switch on. See table below.
- TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
- the reverse direction. This status code will be displayed when the current
- the forward direction. This status code will be displayed when the current
27-23 Motor field current is high on start up in
- draw in the motor field is too high at start up in the reverse direction.
-24 Motor field current is high on start up in
- TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
- draw in the motor field is too high at start up in the forward direction.
- TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
- Volts DC. This status code will be displayed when the controls
- the run mode. This st atus code will be displayed when the current
28-27 Controls power supply is less than 10
- power supply is less than 10 volts.
-28 Motor field current is too high during
- TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
- draw in the motor field is sustained above a preset limit for longer than 70 seconds.
- January 2000
  - TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
29-29 Motor field current is too high during
- the run mode (Dual motor proportioning controls only)
- MEMORY RECALL
- YES CORRECTIVE ACTIONS Circuits valid for Traction Controller
  - SYMPTOM Control will not operate.
- TROUBLE-SHOOTING DIAGRAM
- January 2000
  - TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
30-30 PMT enable signal from auxiliary
- control to master at PL21 is missing during SRO check (Dual motor proportioning controls only)
- MEMORY RECALL
- NO CORRECTIVE ACTIONS Circuits valid for Traction Controller
  - SYMPTOM Auxiliary control shutdown.
- TROUBLE-SHOOTING DIAGRAM
31-41 Open thermal protector (TP) or
- transistor over temperature. This status code will be displayed when the voltage at
- high. This status code will be displayed when the voltage at
-42 Motor armature offset voltage is too
- the thermal protector is too high.
  - MEMORY RECALL
- TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
- the current sensor input is greater than 2.6 volts with no current flowing in the motor circuit.
  - MEMORY RECALL
32-43 Motor armature offset voltage is too
- TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
- properly. This status code will be displayed when, during
-44 Armature transistor did not turn off
- low. This status code will be displayed when the voltage at
- the current sensor input is less than 2.4 volts with no current flowing in the motor circuit.
  - MEMORY RECALL
- TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
- MEMORY RECALL
- TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
- properly. This status code will be displayed when, during
- than 12% of battery volts. This status code will be displayed when the voltage at
33-45 Armature transistor did not turn on
-46 Look Ahead test for A2 volts less
- MEMORY RECALL
- TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
- A2 is less than 12% of battery volts.
  - MEMORY RECALL
34-49 Motor field current is too low during the
- TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
- contactor closes. This status code will be displayed during key on
- run mode. This status code will be displayed when the current
- draw in the motor field is too low during the run mode.
  - MEMORY RECALL
- TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
-51 Capacitor volts are low before the line
- when the capacitor voltage is less than 85% of battery volts at initial key switch on.
  - MEMORY RECALL
- TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
- input too low during running. This status code will be displayed when the voltage
- than 12% of battery volts This status code will be displayed when the control
35-57 Controller motor current sensor
- input from the current sensor is too low during running.
  - MEMORY RECALL
- TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
-64 The line driver input (P2-17) is less
- MEMORY RECALL
- SX TRANSISTOR CONTROL Page 36
- January 2000
- - during the run mode This status code will be displayed when the current limit in the line
  - TRACTION STATUS CODE DESCRIPTION OF
- STATUS CAUSE OF STATUS INDICATION
36-65 The line coil current is too high
-66 The field current exceeds the
- MEMORY RECALL
- YES CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM Circuits valid for Traction Controller
- - TRACTION STATUS CODE DESCRIPTION OF
- STATUS CAUSE OF STATUS INDICATION
  - MEMORY RECALL
- YES CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM Circuits valid for Traction Controller
  - TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
  - armature transistor limit. This status code will be displayed when the armature
37-67 The armature current exceeds the
- transistor exceeds its specific current limit. The control is reset by recycling the key switch.
- January 2000
  - TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
38-68 The PMT enable signal from the
- auxiliary (slave) control to the master control drops below 5V.
- This status code will be displayed when the voltage at the master PL21 drops below 5V.
  - MEMORY RECALL
- YES CORRECTIVE ACTIONS Circuits valid for Traction Controller
  - SYMPTOM Control will not operate.
- TROUBLE-SHOOTING DIAGRAM
- - SX TRANSISTOR CONTROL Page 39
39-69 The power steering coil current is too
-76 Capacitor (1C) voltage too high. This status code will be displayed when the voltage on the
- high during the run mode. This status code will be displayed when the current in the
- MEMORY RECALL
- capacitor goes above limit voltage* during the regenerative braking cycle.
  - MEMORY RECALL
- SX TRANSISTOR CONTROL Page 40
40-77 Motor current is detected during
-82 When armature motor current is greater
- regenerative braking. This status code will be displayed when motoring current is
- detected during the regenerative braking cycle.
  - MEMORY RECALL
- than 400 amps for more than 3.5 sec the armature motor current will be turned off.
- MEMORY RECALL
- =Continued operation of vehicle in high
- motor current condition
  - =Operating control at stall motor current
- for more than 3.5 seconds.
  - =Function 16 is incorrectly adjusted for
- control % on time. - Adjust function per OEM instructions
41-90 Traction motor temperature has
-91 Pump motor temperature has
42-93 Steering pump motor brush wear
43-94 Traction motor brush wear indicator
44-95 Pump motor brush wear indicator has
45-99 Maintenance alert and speed limit. This status code will be displayed when the normal
-117 Card Type selection is invalid. This status code will be displayed when the card type
46NO GRAPHIC FOR THIS STATUS CODE
- -127 Control logic card power supply is less
- 47-128 Armature current is too high during the
- -141 Open thermal protector (TP1) or
- 48-142 Pump Controller motor current
- -143 Pump Controller motor current
- 49-144 Power Transistor (Q1) did not
- -145 Power Transistor (Q1) did not turn on
  - TRANSISTOR PUMP CONTROL Page 50
- 50-146 Look Ahead test for T2 volts
  - =Check for loose connection at P1.
  - January 2000
  - - contactor closes. This status code will be displayed when the capacitor voltage
- -150 Capacitor volts are low after the line
  - less than 12% of battery volts. This status code will be displayed when the voltage at T2 is
  - PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
  - less than 12% of battery volts.
    - MEMORY RECALL
  - YES CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM Circuits valid for Pump Controller
  - - PUMP STATUS CODE
  - DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
    - is less than 85%of the battery voltage in the run mode.
      - MEMORY RECALL
  - YES CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM Circuits valid for Pump Controller
    - SYMPTOM Pump control will not operate. POSSIBLE CAUSE Defective line contactor.
      - =Check for open line contactor power
    - =Check power fuse for open circuit.
    - No battery voltage at P1.
      - =Check for battery voltage at POS and
    - P1.
  - DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
- 51-151
  - NO CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM Circuits valid for Pump Controller
- -157 Controller motor current
  - STATUS CAUSE OF STATUS INDICATION
  - NO CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM Circuits valid for Pump Controller
- 52-180 Voltage at capacitor (1C) is less than
- -181 Battery voltage is less than 14
  - 55Section 6. SX FAMILY GE HANDSET INSTRUCTIONS
    - =Battery Voltage ( 36/48 volts is auto ranging ) =Selection of Card Operation Type.
  - 56SET-UP MODE
    - 8 8 8 8
    - 125
    - 0 8 5
    - 125
- 57LX
  - g
  - 1 5
  - + + 9 13
  - 2 6 10 14
  - 3 7 11 15
  - 4 8 12
60[(
- =Pick up steer pump contactor on seat switch closure
- =Pick up steer pump contactor on directional switch
(
[
- ADJUSTABLE FEATURES
- ZERO
  - SX TRANSISTOR CONTROLS Page 63
    - January 2000
  - Section 6.5 Summary of Current Limit Adjustments
- MAXIMUM
- ZERO MAXIMUM
- 63FIELD CURRENT
- ARMATURE CURRENT
  - =LED graphics to display Battery Discharge Indication
- 67g
  - =Various LED indicators for Maintenance Required Status
  - =A push-button associated with the four segment LED that
  - IC3645LXTDD T 3
    - + -
  - 68g
    - PY3 PY4 PY2 PY1 PY5
    - PY3 PY4 PY2 PY1
    - Wiring connections to "Y" plugs of Traction & Pump controls.
    - 69Section 8.0 TURN ANGLE POTENTIOMETER INSTALLATION
      - LEFT TURN RIGHT TURN
  - 70320 DEGREE POTENTIOMETER FOR STEER ANGLE INPUT
    - Figure 2