GE IC3645SP4U400N3, IC3645SR4U404N2 operation manual Reconnect plugs, Cleaner, 328A1777G1

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL

Section 4.3 Recommended Lubrication of Pins and Sockets Prior to Installation

Beginning in January of 1999, GE will implement the addition of a lubricant to all connections using pins and sockets on EV100/EV200 and Gen II products. Any connection made by GE to the A, B, X, Y, or Z plugs will have the lubricant NYE 760G added to prevent fretting of these connections during vehicle operation.

Fretting occurs during microscopic movement at the contact points of the connection. This movement exposes the base metal of the connector pin which, when oxygen is present, allows oxidation to occur. Sufficient build up of the oxidation can cause intermittent contact and intermittent vehicle operation. This can occur at any similar type of connection, whether at the control or in any associated vehicle wiring, and the resultant intermittent contact can provide the same fault indication as actual component failure.

The addition of the NYE 760G lubricant will prevent the oxidation process by eliminating the access of oxygen to the contact point. GE recommends the addition of this lubricant to the 12 pin and 23 pin plugs of all new Gen II controls at the time of their installation into a vehicle

When servicing existing vehicles exhibiting symptoms of intermittent mis-operation or shutdown by the GE control, GE recommends the addition of this lubricant to all 12 and 23 pin plugs, after proper cleaning of the connectors, as a preventative measure to insure fretting is not an issue before GE control replacement. Also, for long term reliable control operation, the plug terminals must be maintained per these instructions with the recommended contact cleaner and lubricant which provides a high degree of environmental and fretting protection.

New and re-manufactured control plugs are cleaned and lubricated prior to shipment from the factory. However, in applications where severe vibration or high temperature cycling and excessive humidity ( such as freezers ) are present, it is recommended that the plug terminals be cleaned and lubricated every year, per this instructions. In normal applications, plug maintenance should be performed every two years, unless intermittent problems arise with the plugs, requiring more immediate attention.

Warning: Do not use any other cleaners or lubricants other than the ones specified.

WARNING: Before conducting maintenance on the vehicle, jack up the drive wheels, disconnect the battery and discharge the capacitors. Consult the Operation and Service Manual for your particular vehicle for details on discharging the capacitors; this procedure differs between SCR and Transistor controls.

1.Disconnect plug from controller or mating plug.

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2.Locate the plug that contains the socket (female) terminals. Maintenance needs only to be performed on the plug containing the socket (female) type terminals. Reconnecting the plugs will lubricate the pin (male) terminals.

3. Clean each terminal using Chemtronics contact cleaner “Pow-R-WasH CZ “ as shown in Figure 1.

							s
						c
				oni
			tr
	m
he								er
C
						an
					le
				tc
			ac
		nt
	co					C		Z
		-
			RH
				-s
				wa
								W
					o
					P
										e
									an
								oz
								cir

Figure 1

4. Lubricate each terminal using Nye 760G lubricant as

shown in figure 2. Apply enough lubricant to each terminal opening to completely fill each opening to a depth of .125” minimum.

LUNye

B

RICA

N

TS

Figure 2

5.Reconnect plugs.

Reference
Cleaner	Chemtronics Pow-R-WasH CZ Contact
	Cleaner
Lubricant	Nye Lubricants NYOGEL 760G
GE Plug Lub Kit	Contains both above products:
	328A1777G1

January 2000