GE EV100 LX Instructions Manual Download | Manualshive

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11

TERMINAL

CONNECTIONS

FOR

LX/LXT

LOGIC

CARDS

TRACTION

TRACTION

TRACTION

TRACTION

INPUT

STANDARD

SL/FW

REGEN/FW

DUAL

MTR

PUMP

TB1

Accel

Pot

Input

Accel

Pot

Input

Accel

Pot

Input

Accel

Pot

Input

Accel

Pot

Input

TB2

Start

Switch

Input

Start

Switch

Input

Start

Switch

Input

Start

Switch

Input

SL1

TB3

Seat

Switch

Input

Seat

Switch

Input

Seat

Switch

Input

Seat

Switch

Input

SL2

TB4

Key

Switch

Input

Key

Switch

Input

Key

Switch

Input

Key

Switch

Input

Key

Switch

Input

TB5

Forward

Switch

Input

Forward

Switch

Input

Forward

Switch

Input

Forward

Switch

Input

SL3

TB6

Reverse

Switch

Input

Reverse

Switch

Input

Reverse

Switch

Input

Reverse

Switch

Input

SL4

PA1

Plug

Signal

Plug

Signal

Plug

Signal

PS

Coil

Driver

Status

Code

93

Input

PA2

BDI

Interrupt

BDI

Interrupt

BDI

Interrupt

BDI

Interrupt

Status

Code

93

Input

PA3

Aux

Hourmeter

Input

Aux

Hourmeter

Input

Aux

Hourmeter

Input

Aux

Hourmeter

Input

Status

Code

90

Input

PA4

Not

Used

SL2

Sensor

2

Yellow

Wire

In-Board

Mtr

Rev

Sw

Status

Code

94

Input

PA5

Not

Used

SL3

Sensor

2

Green

wire

Right

Mtr

Dropout

Sw

Status

Code

94

Input

PA6

Not

Used

SL1

Mtr

A2

Input

Left

Mtr

Dropout

Sw

Status

Code

91

Input

PB

1

FW

Coil

Driver

FW

Coil

Driver

FW

Coil

Driver

F

Rht

Mtr

Coil

Driver

Status

Code

95

Input

PB

2

Not

Used

Not

Used

Regen

Coil

Driver

F

Lft

Mtr

Coil

Driver

Status

Code

95

Input

PB

3

SP

Coil

Driver

SP

Coil

Driver

SP

Coil

Driver

R

Rht

Mtr

Coil

Driver

BDI

Enable

Signal

Input

PB

4

F

Coil

Driver

F

Coil

Driver

F

Coil

Driver

R

Lft

Mtr

Coil

Driver

Pump

(PMT)

C

oil

Driver

PB

5

R

Coil

Driver

R

Coil

Driver

R

Coil

Driver

1A

coil

Driver

1A

Coil

Driver

PB

6

1A

Coil

Driver

1A

Coil

Driver

1A

Coil

Driver

D

Coil

Driver

Status

Code

92

Input

PY1

Dash

Display

4

Input

Dash

Display

4

Input

Dash

Display

4

Input

Dash

Display

4

Input

Dash

Display

4

Input

PY2

Dash

Display

3

Input

Dash

Display

3

Input

Dash

Display

3

Input

Dash

Display

3

Input

Dash

Display

3

Input

PY3

Dash

Display

1

Input

Dash

Display

1

Input

Dash

Display

1

Input

Dash

Display

1

Input

Dash

Display

1

Input

PY4

Dash

Display

2

Input

Dash

Display

2

Input

Dash

Display

2

Input

Dash

Display

2

Input

Dash

Display

2

Input

PY5

Dash

Display

5

Input

Dash

Display

5

Input

Dash

Display

5

Input

Dash

Display

5

Input

Not

Used

PY6

Not

Used

Not

Used

Not

Used

Not

Used

Not

Used

PY7

Im

Im

Im

Not

Used

Not

Used

PY8

TMMA-9

/ Pump-PY12

TMMA-9

/ Pump-PY12

TMMA-9

/ Pump-PY12

TMMA-9

/ Pump-PY12

Not

Used

PY9

TMMA-7

/ Pump-PY11

TMMA-7

/ Pump-PY11

TMMA-7

/ Pump-PY11

TMMA-7

/ Pump-PY11

Not

Used

PY10

TMMA-2

/ Pump-PY10

TMMA-2

/ Pump-PY10

TMMA-2

/ Pump-PY10

TMMA-2

/ Pump-PY10

Traction

PY10

PY11

Not

Used

Not

Used

Not

Used

Not

Used

Traction

PY9

PY12

Not

Used

Not

Used

Not

Used

Not

Used

Traction

PY8

PY13

Not

Used

Not

Used

Not

Used

Not

Used

Not

Used

PY14

Not

Used

Not

Used

Not

Used

Not

Used

Not

Used

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Summary of Contents for EV100 LX

Page 1: ...variations in equipment nor to provide for every possible contingency to be met with installation operation or maintenance Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser s purpose the matter should be referred to the truck manufacturer through his normal service channels not directly to the General Electric Company Sep...

Page 2: ...BASE APPLICATIONS LESS THAN 200 FLLR ARGUMENT NO 03 APPLICATION AND 1 REC OPTIONS T1 STANDARD CURRENT LIMIT TRACTION T2 HIGH PERFORMANCE CURRENT LIMIT TRACTION P1 STANDARD CURRENT LIMIT PUMP P2 HIGH PERFORMANCE CURRENT LIMIT PUMP ARGUMENT NO 04 LOGIC CARD OPTIONS MX TRACTION DUAL MOTOR WITHOUT BDI MT TRACTION DUAL MOTOR WITH BDI PX PUMP CONTROL WITH TMM TX TRACTION WITHOUT BDI TT TRACTION WITH BDI...

Page 3: ...3 EV100LX COMPONENT LOCATIONS ...

Page 4: ...4 EV100LX OUTLINE DRAWING ...

Page 5: ...5 EV100LX WITH SPEED LIMIT AND FW 9 ...

Page 6: ...6 EV100LX WITH REGEN AND FW 9 ...

Page 7: ...7 EV100LX DUAL MOTOR CONTROL 9 ...

Page 8: ...8 EV100LX PUMP CONTROL 9 ...

Page 9: ...ISTOR ASM 01 30 171B3940G1 SNUBBER ASM 04 34 44A718897 001 CAPACITOR MTG STRAP 02 37 148B5620DPP1 BUS BAR 01 38 148B5620DPP2 BUS BAR 01 39 148B5620DPP4 BUS BAR 01 40 148B5620DPP3 BUS BAR 01 43 WH7138R36G1 WIRE HARNESS 01 48 L201P17B33 NUT M8X1 25MM 02 49 L400P10B33 M8 FLAT WASHER 05 50 L401P27B33 M8 LOCK WASHER 05 52 44A723274 001 M5X50MM T R SCREW 04 53 44A723274 002 M5X26MM T R SCREW 07 54 L14P1...

Page 10: ...10 EV100LX PART NUMBER IDENTIFICATION ...

Page 11: ... Driver F Lft Mtr Coil Driver Status Code 95 Input PB3 SP Coil Driver SP Coil Driver SP Coil Driver R Rht Mtr Coil Driver BDI Enable Signal Input PB4 F Coil Driver F Coil Driver F Coil Driver R Lft Mtr Coil Driver Pump PMT Coil Driver PB5 R Coil Driver R Coil Driver R Coil Driver 1A coil Driver 1A Coil Driver PB6 1A Coil Driver 1A Coil Driver 1A Coil Driver D Coil Driver Status Code 92 Input PY1 D...

Page 12: ...3645LXCD1M Standard Displayed to Handset or Dash Display Standard Displayed to Handset or Dash Display Standard Standard Enable Disable Features Adjustable 2 to 15 On Time Adjustable See C L Curves Standard High Performance Adjustable 200 to 930 Amps Adjustable 100 to 930 amps Can be Disabled Standard Standard with 1A Ctr Adjustable 1 to 22 seconds Follows CA by 2 seconds with Accel Volts is 5V or...

Page 13: ...mps Not Available Not Available Adjustable Regen C L 75A to 630A Regen Start 15 to 96 Adjustable Pick up 52A 466A Drop out 65A to 895A Standard Adjustable Input by Limit Switch Seat 5 to 63 sec Neutral 5 to 63 sec 24 80 VDC 5000 0 Ohms 3 5 0 VDC Standard 50 at 36 80 VDC 75 at 24 VDC Standard 30 to 50o C 5 5 Kg On Board On Board Not Applicable Not Applicable On Board On Board Standard Standard Logi...

Page 14: ...andard Standard Optional 150 Amps Plus 103 Amps Plus 330 950 Amps 330 650 Amps 405 640 Amps STD 320 565 Amps STD 230 495 Amps STD 475 690 Amps H P 455 685 Amps H P 435 680 Amps H P IC3645LXCD1M Standard Standard Optional 150 Amps Plus 103 Amps Plus 330 950 Amps 330 650 Amps 405 640 Amps STD 320 565 Amps STD 230 495 Amps STD 475 690 Amps H P 455 685 Amps H P 435 680 Amps H P IC3645LXCD1P Standard S...

Page 15: ... to the battery 5REC turns on and allows current to flow T4 T3 lC lREC 5REC to T4 T3 This current charges the bottom of lC positive with respect to the battery positive bus This charging cycle occurs in less than l millisecond 00l sec and 5REC shuts off This charge is now stored on the capacitor until it is time to turn off lREC Current continues to flow in lREC until the control card fires 2REC W...

Page 16: ...nter operating condition of the oscillator is at 50 percent ON time with a nominal l 8 milliseconds ON time and l 8 millisecond OFF time This corresponds to a maximum operating frequency of about 300 hertz At creep the ON time will decrease to approximately 0 8 milliseconds while OFF time will become in the order of 20 milli seconds At full SCR operation this condition will be reversed short OFF t...

Page 17: ...t in feature provides smooth transition from SCR to lA bypass This is accomplished by the SCR continuing to pulse until the lA contactor power tips close CONTROL ACCELERATION AND 1A TIME This feature allows for adjustment of the rate of time it takes for the control to accelerate to 96 applied battery voltage to the motor on hard accel eration The 1A contactor will automatically close 2 seconds af...

Page 18: ... will not allow the control to start under the following conditions 1 If 1REC is shorted or if 1A contactor is welded the control will not allow the F or R contactor to close 2 Will not allow the control to operate if F and R internal coil drivers are shorted or if 3REC diode is shorted The PMT circuit will shut down operation of the control opening of the F or R contactor under the followingcondi...

Page 19: ...el the plugging mode transitions to regenerative braking mode Transitioning to regenerative braking mode opens the RB contactor disconnecting the motor arma ture from battery negative and inserting 7REC and REGEN SENSOR 2 in the regen circuit During the lREC on time the field and armature current is increased During the 1REC off time the energy stored in the field and armature generates the regene...

Page 20: ...on 1 provides a 5 to 63 second time delayed drop out of the steer pump contactor when the Forward or Reverse directional switch is opened This is overridden by a 1 5 second time delayed drop out whenever the seat switch is opened Option 2 provides a 5 to 63 second time delayed drop out of the SP contactor when the seat switch is opened CONSTANT CURRENT COIL DRIVERS AND INTERNAL COIL SUPPRESSION Th...

Page 21: ...nd Truck Management Module TMM Along with the status code display from the TMM the logic card is capable of reducing the current to the control to alert the operator of a critical fault condition BATTERY DISCHARGE INDICATION This feature uses the latest in microprocessor technol ogy to provide accurate battery state of charge information and supplies passive and active warning signals to the vehic...

Page 22: ...point 1 TB2 to SCR control negative Speed point 1 is adjustable by function 11 to adjust motor voltage from 0 to full motor volts The specified motor volts will be regulated however the magnitude of motor current will vary depending on the loading of the vehicle The second speed is obtained by closing speed point 2 TB3 to SCR control negative Speed point 2 is adjustable by function 12 to adjust mo...

Page 23: ...nterrupt will disable the hydraulic controller if the connec tion between PB3 and PB6 is opened If a BDI circuit is not used a jumper must be placed between PB3 and PB6 to allow the hydraulic control to operate The following are the input output terminals for the pump control TB1 Accelerator Input TB2 SL1 Input TB3 SL2 Input TB4 Key Switch Input TB5 SL3 Input TB6 SL4 Input PA1 93 Status Code Input...

Page 24: ...l and then blow completely dry with low pressure air The control can also be cleaned with Freon TF degreaser For the SCR panel to be most effective it must be mounted against the frame of the truck The truck frame acting as an additional heat sink will give improved truck performance by keeping the SCR control package cooler The use of a heat transfer grease Dow Corning 340 is recommended Terminal...

Page 25: ...rect problem The same device designations have been maintained on different controls but the wire numbers may vary Refer to the elementary and wiring diagrams for your specific control The wire numbers shown on the elementary diagram will have identical numbers on the corresponding wiring diagrams for a specific truck but these numbers may be different from the numbers referenced in this publica t...

Page 26: ... new reactor on SCR base and start screws back into base Be sure to use the original screws and washers run screws in to base finger tight Check that the bottom of the reactor is flat against the base Alternately tighten the two screws by 1 4 turn until firm Replace all connections removed in step 1 ...

Page 27: ...t to cover all variations in equipment nor to provide for every possible contingency to be met with installation operation or maintenance Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser s purpose the matter should be referred to the vehicle manufacturer through his normal service channels not directly to the General Ele...

Page 28: ...age is present between PZ7 and PZ3 control negative and that voltage is present between TB4 and PZ3 control negative Open circuit between logic card plug Y and Dash Display or Handset Check for a loose connection or open wire between logic card plug Y and Dash Display or Handset Defective Dash Display or Handset Replace Dash Display or Handset Figure 1 Figure 1 CONTROL T Y P E SYMPTOM Forward or r...

Page 29: ...ional switch to insure that it opens when the directional switch is returned to neutral Short circuit between TB2 and TB5 Disconnect the wire from TB5 and check for a short circuit between TB2 and the wire Defective logic card Disconnect wire at TB5 Measure voltage at TB5 should be less than 60 of battery volts Reverse directional switch is closed on initial power up SYMPTOM Reverse contactor will...

Page 30: ...sive leakage from TB2 to battery negative Check voltage at TB2 with key and seat switches closed and directional switch in neutral Voltage should be greater than 60 of battery voltage If less than 60 battery voltage Remove wire and measure ohmic value from wire to SCR negative Value should be less than 22k ohms STATUS INDICATION CRITERIA This status code is displayed when TB2 voltage is less than ...

Page 31: ...een directional switch s and TB5 or TB6 Check all control wires and connections shown in Figure 1 SYMPTOM Forward or reverse contactor picks up but control will not operate whenacceleratorpedalisdepressedorstatuscode 07isdisplayed thendisappearswhenthevehiclestartstoaccelerate POSSIBLE CAUSE Acceleratorinputmis adjustedordefective Input voltage at TB1 should be less than 3 7 volts Ad justorreplace...

Page 32: ...d be more than 3 0 volts Adjust or replace accelerator unit to insure that the voltage at TB1 is more than 3 0 volts before depress ing pedal Short circuit between battery negative and TB1 in accelera tor input circuit Disconnect wire from TB1 Check for short circuit from wire to battery negative Resistance should be greater than 4 7K ohms Defective Card Disconnect wire from TB1 Measure voltage fr...

Page 33: ...roper adjustment for battery being used See handset instruction sheet for details Adjust to proper settings This status code is displayed when the battery volts are less than 1 95 volts per cell at initial start up See table in figure 1 SYMPTOM Forward and reverse contactor will not pick up POSSIBLE CAUSE Incorrect control card adjustment Check function 15 for proper adjustment for battery being u...

Page 34: ...erse contactor will not pick up Status code may alternate between code 23 and code 24 Complete check for code 23 if the problem is not found perform check for code 24 POSSIBLE CAUSE Defective F and R contactor coil circuit Check for open circuit or loose connection between PB4 and positive side of F contactor coil and between PB5 and positive side of R contactor coil Remove plug B Check ohmic valu...

Page 35: ...status code is furnished as a troubleshooting aid for status code 46 Defective 1A contactor Check 1A contactor for binding or slow operation when dropping out SYMPTOM SCRcontroldoesnotoperate Statuscodemayalternatebetween code 23 and code 24 Complete checks for 24 if the problem is not found perform code 23 check POSSIBLE CAUSE Defective F or R contactor F or R power tips fail to close because 1 W...

Page 36: ...STATUS INDICATION CRITERIA This status code is displayed when the voltage between PZ1 and PZ5 is greater than 1 8 volts Open thermal protector TP or control over temperature SYMPTOM Reduced or no power to traction motor in SCR range POSSIBLE CAUSE Open thermal protector circuit Check for loose connection or broken wire be tween Black wire Thermal proctor and PZ1 Gray wire Thermal proctor and PZ5 D...

Page 37: ...d STATUS INDICATION CRITERIA This status code is displayed when voltage between PY7 and negative is greater than 1 6 volts with no current flowing in the motor circuit Control motor current sensor input missing STATUS INDICATION CRITERIA This status code is displayed when voltage between PY7 and negative is less than 84 volts with no current flowing in motor circuit SYMPTOM Stall currents in SCR r...

Page 38: ...C out of specification No field test is possible Replace 1 REC after above checks show no problem found STATUS INDICATION CRITERIA This status code is displayed when during SCR operation 1 REC fails to turn off SYMPTOM Forward or reverse contactor will open and close then open and then can only be closed by opening and closing the key switch POSSIBLE CAUSE Defective 2 REC circuit Check for shorted...

Page 39: ... open and close then open and then can only be closed by opening and closing the key switch POSSIBLE CAUSE Defective 2 REC circuit Check that 2 REC will gate on Check for open circuit or loose connection between 2 REC gate and PZ10 white red wire Check for open circuit or loose connection 1 REC and 1C through the 2 REC circuit F or R contactor or power tips bouncing open Check that power tips on F...

Page 40: ...battery volts STATUS CODE 49 DESCRIPTION No MEMORY R E C A L L CONTROL T Y P E Traction Figure 1 SYMPTOM Forward or reverse contactor will open and close then open and then can only be closed by opening and closing the key switch POSSIBLE CAUSE Defective 5 REC circuit Check for shorted 5 REC Check for shorted 5 REC snubber 25 REC Check that 5 REC will gate on Check for open circuit or loose connec...

Page 41: ...0 white red wire Check 2 REC to insure that it will gate on STATUS INDICATION CRITERIA This status code is displayed when 2 REC circuit fails to turn on at initial start up STATUS INDICATION CRITERIA This status code is displayed when capacitor volts exceed 225 volts and motor current is greater than 300 amps SYMPTOM Forward or reverse contactors open and close then can only be closed by opening a...

Page 42: ...rd for open and loose connection Defective motor circuit Check motor circuit for open or loose connections Check motor brushes for proper seating F or R contactor power bouncing open Insure that F and R contactor does not bounce open during vehicle operation ie traveling over speed bumps and dock plates STATUS CODE 52 DESCRIPTION Excessive capacitor voltage when motor current is low Yes MEMORY R E...

Page 43: ...se connections Reversed power cable connection Insure that the battery negative cable connects to SCR NEG and the motor A2 cable connects to SCR A2 STATUS INDICATION CRITERIA This status code is displayed when the voltage input to PZ4 and PZ3 is the wrong polarity DESCRIPTION Shorted F R or 1A contactor coil driver No MEMORY R E C A L L CONTROL T Y P E Traction Figure 1 STATUS CODE 54 SYMPTOM Cont...

Page 44: ... Check yellow sensor wire for open circuit or loose connection between sensor welded connection and PA4 STATUS CODE 71 DESCRIPTION Regen current sensor input missing green wire Yes MEMORY R E C A L L CONTROL T Y P E Traction Figure 1 STATUS INDICATION CRITERIA This status code is displayed when input signal at PA5 is missing SYMPTOM Control does not operate POSSIBLE CAUSE Defective regen sensor in...

Page 45: ... the A2 connection of the RB contactor STATUS CODE 73 DESCRIPTION Regen contactor does not drop out or drops out slowly Yes MEMORY R E C A L L CONTROL T Y P E Traction Figure 1 STATUS INDICATION CRITERIA This status code is displayed when the RB contactor power tips fail to open after 100 milliseconds after power is removed from the RB contactor coil SYMPTOM Forward or reverse contactor opens and ...

Page 46: ...TION 1 REC fails to turn off during Regen Yes MEMORY R E C A L L CONTROL T Y P E Traction Figure 1 STATUS INDICATION CRITERIA This status code is displayed when any failure of 1 REC to turn off during regen cycle SYMPTOM Forward or reverse contactor opens and closes then opens and can only close by opening and closing the key switch POSSIBLE CAUSE 1 REC turn off failure not related to regen Stall ...

Page 47: ...atus code is displayed when the voltage at terminal 1 of TMM is at zero volts STATUS CODE 76 DESCRIPTION Capacitor overvoltage during Regen Yes MEMORY R E C A L L CONTROL T Y P E Traction Figure 1 STATUS INDICATION CRITERIA This status code is displayed when capacitor voltage is greater than 225 volts during the regen cycle SYMPTOM Forward or reverse contactor opens and closes then opens and can o...

Page 48: ... with internal TMM function input terminal is PA6 on pump logic card STATUS INDICATION CRITERIA This status code is displayed when the voltage at terminal 3 of TMM is at zero volts STATUS INDICATION CRITERIA This status code is displayed when the voltage at terminal 4 of TMM is at zero volts User defined status code see OEM instructions manual SYMPTOM Status code flashes on and off POSSIBLE CAUSE ...

Page 49: ...gic card STATUS INDICATION CRITERIA This status code is displayed when the voltage at terminal 5 and 6 of TMM is at zero volts User defined status code see OEM instructions manual User defined status code see OEM instructions manual SYMPTOM Status code flashes on and off POSSIBLE CAUSE User defined status code is displayed by switch closure or motor brush sensor closure to negative See OEM instruc...

Page 50: ...is at zero volts SYMPTOM Status code flashes on and off POSSIBLE CAUSE User defined status code is displayed by switch closure or motor brush sensor closure to negative See OEM instruction manual for corrective action required Other Causes Terminal 11 and 12 shorted to negative Defective input switch shorted Defective TMM card NOTE When SCR pump control is used with internal TMM function input ter...

Page 51: ...n value is set to an invalid number SYMPTOM Pump contactor will not pick up Status code may alter nate between code 23 and code 24 Complete check for code 23 if the problem is not found perform check for code 24 POSSIBLE CAUSE Defective Pump contactor coil circuit Check for open circuit or loose connection between PB4 and positive side of Pump contactor coil Remove plug A Check ohmic value from PB...

Page 52: ...normally closed power tips 2 Binding contactor tip assembly 3 Defective Pump contactor coil See status code 123 Open motor circuit Check for open circuit or loose connection in motor circuit from the A1 connection to the A2 connection on the control panel Defective 1A contactor Perform checks as outlined in status 123 STATUS INDICATION CRITERIA This status code is displayed when T2 volts is greate...

Page 53: ...ect wires from PZ1 and PZ5 At room temperature 25o C or 75o F measure resistance between black and gray wire Replace TP if ohmic value is greater than 300 ohms SCR is in thermal cut back Allow control to cool status code should disap pear STATUS CODE 142 DESCRIPTION Control motor current sensor input missing No MEMORY R E C A L L CONTROL T Y P E Pump Figure 1 SYMPTOM No power to pump motor in SCR ...

Page 54: ...144 DESCRIPTION 1REC did not turn off properly Yes MEMORY R E C A L L CONTROL T Y P E Pump Figure 1 STATUS INDICATION CRITERIA This status code is displayed when during SCR operation 1 REC fails to turn off SYMPTOM Forward or reverse contactors open and close then can only be closed by opening and closing the key switch POSSIBLE CAUSE Defective 5 REC circuit Check for shorted 5 REC Check for short...

Page 55: ...e wire Defective 1 REC Intermittent or open 1 REC gate Field test may or may not show defect Replace 1 REC after above checks show no problem found STATUS INDICATION CRITERIA This status code is displayed when 1 REC fails to gate on STATUS CODE 146 DESCRIPTION Look ahead test for T2 volts Greater than 85 of battery volts No MEMORY R E C A L L CONTROL T Y P E Pump Figure 1 SYMPTOM Pump contactor wi...

Page 56: ... not bounce open during operation ie travel over speed bumps or dock plates STATUS INDICATION CRITERIA This status code is displayed when the 2 REC fails to turn on 2REC does not turn properly STATUS CODE 148 DESCRIPTION No MEMORY R E C A L L CONTROL T Y P E Pump Figure 1 SYMPTOM Pump contactor will not pick up POSSIBLE CAUSE Defective forward or reverse contactor Check for welded forward or rever...

Page 57: ... loose connections at capacitor terminals STATUS INDICATION CRITERIA This status code is displayed when the 5 REC circuit fails to turn on 5 REC does not turn on properly STATUS CODE 150 DESCRIPTION No MEMORY R E C A L L CONTROL T Y P E Pump Figure 1 SYMPTOM Pump contactor picks up Control does not operate POSSIBLE CAUSE Defective 2 REC circuit Open circuit or loose connection between spider assem...

Page 58: ...xcessive capacitor voltage when motor current is high STATUS CODE 152 DESCRIPTION Excessive capacitor voltage when motor current is low Yes MEMORY R E C A L L CONTROL T Y P E Pump Figure 1 STATUS INDICATION CRITERIA This status code is displayed when capacitor volts exceed 225 volts and motor current is less than 200 amps SYMPTOM Pump contactors open and close then can only be closed by opening an...

Page 59: ...tage polarity check No MEMORY R E C A L L CONTROL T Y P E Pump Figure 1 SYMPTOM Pump contactors open and close then can only be closed by opening and closing the key switch POSSIBLE CAUSE Reversed yellow and green current senors wires Insure that the green wire connects to PZ4 with no open circuits yellow wire connects to PZ3 with no open circuits or loose connections Reversed power cable connecti...

Page 60: ...6 0 ...

Page 61: ...ctions for Removal of Control Card Remove control wires on the screw terminals 1 through 6 as required Unplug A B and Z plugs by pressing down on tab with wide blade screwdriver and rotating 90 degrees Remove the two mounting screws and lift card box free NOTE Do not attempt to remove circuit broad from card box Reverse procedures to install new control card Mounting A and B Plugs Terminals 1 6 Y ...

Page 62: ...k operation of the potentiometer disconnect the battery and disconnect the wire at control card TB1 Connect a VOM to the wire that was removed from TB1 and to nega tive Place the VOM on the R x 100 scale With the accelerator in the creep speed position the ohms reading should be 4800 to 6000 ohms With the accelerator in the top speed position the ohm reading should be 50 ohms or less With the wire...

Page 63: ...enfromthecathodeto the gate terminal R x100 scale If resistance reads either zero ohms short or infinity ohms open replace the SCR When reassembling SCR s refer to TABLE 5 Rectifiers 3REC 4REC Diode Blocks When checking diodes disconnect battery and discharge capacitor 1C When replacing rectifiers refer to TABLE 5 For 3REC and 4REC disconnect one lead or flexible connec tion 3REC and 4REC are diod...

Page 64: ... capacitor action is not observed replace the filter block Filter Block 23FIL etc Filter block test 4K is only to detect an open or shorted filter If the control has symptoms as in 1E interchange 22REC and 25REC and try again If the problem is corrected the old 25REC is marginal and should be replaced If the problem is not corrected replace both filters 1X Choke and Reactor T3 T4 Refer to panel wi...

Page 65: ...he base and smooth the insulator into position NOTE Insulator not required for 2REC and 5REC Coat insulator with a light coat of heat transfer grease similar to GE 350 Set new module on insulator and start screws back into base Be sure to use the original screwsandwashers runscrewsintobase fingertight Check that the bottom of the module is flat against the insulator or base Alternately tighten the...

Page 66: ...et new reactor on SCR base and start screws back into base Be sure to use the original screwsandwashers runscrewsintobase fingertight Check that the bottom of the reactor is flat against the base Alternately tighten the two screws by 1 4 turn until firm Replace all connections removed in step 1 ...

Page 67: ... intermittent random status code Monitor battery state of charge on LXT systems Monitor hourmeter reading on traction and pump SCR systems Monitor or adjust the following control functions Creep speed Controlled Acceleration and 1A time Current Limit Steer pump time delay and define signal input seat switch or directional switch Plugging distance Current Pedal position plug range or disable 1A dro...

Page 68: ...8888 Segment check turn on key displayed Push function U 005 Selected number function number is displayed After one second 085 Stored value for time delay the function is displayed Push CONT 085 Displayed value will blink Change value with 125 Value changes adjustment knob while blinking Push STORE 125 New value stored and blinking stops Push ESC 8888 Segment check displayed At this point another ...

Page 69: ... 2 4 amps per set unit Example Setting of 20 84 amps DESCRIPTION OF FUNCTION NUMBERS FOR Control Cards IC3645EVLXCD1TT AND IC3645EVLXCD1TX FUNCTION 1 STORED FAULT CODE Push 1 This function register contains the last fault that shut down vehicle operation PMT type fault that is reset by cycling the key switch This fault code will be over written each time a new fault occurs and can be cleared from ...

Page 70: ...d FUNCTION 12 SPEED LIMIT 2 SL2 Push 12 Same as Function 11 except using SL2 limit switch for input FUNCTION 13 SPEED LIMIT 3 SL3 Push 13 Same as Function 11 except using SL3 limit switch for input The SL3 set speed limit is also activated by the Truck Management Module fault codes 90 and 93 See instructions for IC3645TMM1A Truck Management Module for details FUNCTION 14 INTERNAL RESISTANCE COMPEN...

Page 71: ... application The table below shows the setting to select card application type depending on which control card is used EV100 Standard Speed Function with FW Limit Regen FW STD C L 0 to 4 20 to 24 40 to 44 High C L 5 to 9 25 to 29 45 to 49 STD C L Auto plug 10 to 14 30 to 34 50 to 54 High C L Auto plug 15 to 19 35 to 39 55 to 59 EV200 Standard Speed Function with FW Limit Regen FW STD C L 64 to 68 ...

Page 72: ...and negative Set 128 or greater to select option 1 above Set 0 127 to select option 2 above DESCRIPTION OF FUNCTION NUMBERS FOR Control Cards IC3645EVLXCD1MT AND IC3645EVLXCD1MX FUNCTION 1 STORED FAULT CODE Push 1 This function register contains the last fault that shut down vehicle operation PMT type fault that is reset by cycling the key switch This fault code will be over written each time a ne...

Page 73: ... 2 11 44 07 63 17 01 34 00 89 3 07 60 05 07 18 01 27 00 85 4 05 72 03 81 19 01 20 00 80 5 04 57 03 05 20 01 14 00 76 6 03 81 02 54 21 01 09 00 73 7 03 27 02 18 22 01 04 00 69 8 02 86 01 91 23 00 99 00 66 9 02 54 01 69 24 00 95 00 63 10 02 28 01 52 25 00 91 00 61 11 02 08 01 39 26 00 88 00 59 12 01 90 01 27 27 00 85 00 57 13 01 76 01 17 28 00 82 00 55 14 01 63 01 08 29 00 79 00 53 15 01 52 01 01 30...

Page 74: ...ns supplied by the manufacturer Card type selection must be made within the capabilities of the SCR control panel used and the supporting electro mechanical devices Failure to com ply with proper application standards could result in misoperation or damage to the control and or motors FUNCTION 18 STEER PUMP TIME DELAY Push CONT and 3 Thisfunctionallowsfortheselectionofsteerpumpcontactor pick up in...

Page 75: ...rating instructions for the control used in your vehicle Range See control C L curves Set 0 to 255 Example 0 min current 255 max current FUNCTION 11 SPEED LIMIT 1 SL1 Push 11 This function allows for the adjustment of the speed limit maximum battery volts to the motor when the SL1 limit switch input signal is received by the control card SL1 limit switch is a normally open switch connected to batt...

Page 76: ... 62 High C L BDI Lockout 27 to 35 63 to 71 BDI Lockout means that the BDI signal from the traction control must be present in order for the pump control to operate This control will stop operation when the battery state of charge reaches 10 Settings for these functions should be made in between the values shown Warning These setting must be changed by authorized personnel only following instructio...

Page 77: ...ral The EV100LX instructions and operating information is applicable to the EV200LX The only difference in the two control types is that the EV200 has a high current rating than the EV100LX a larger mounting foot print and different component parts Standard Outline Drawing ...

Page 78: ...P1L HEAT SINK 1 12 273A2523P11 THERMAL CONDUCTIVE 1 13 116C6961P1L HEAT SINK 1 14 273A2523P12 THERMAL CONDUCTIVE 1 15 259A9208PXCR RECTIFIER 1 16 171B3940G1 SNUBBER ASM 1 17 195B4039G1 SNUBBER MOUNT 1 19 116C6975G1 SPIDER ASM 1 20 273A2523P6 THERMAL CONDUCTIVE 1 21 273A2523P9 THERMAL CONDUCTIVE 1 22 171B3912G1 TERMINAL POST 2 23 259A9053P2 CAPACITOR 2 24 259A8733P1 CAPACITOR MOUNTING BRACKET 2 26 ...

Page 79: ...ER DESCRIPTION QTY EACH 30 44A717068 001 RECTIFIER 1 31 44A727009 G06 THERMISTOR ASM 1 35 195B6250P2 FLEX BUS 4 36 195B6250P11 FLEX BUS 4 37 202B1621P3 CAPACITOR STRAPS 8 38 148B5620EPP3 BUS BAR 1 39 148B5620EPP1 BUS BAR 1 40 148B5620EPP2 BUS BAR 1 41 259A3290P1 INSULATING BUSHING 4 ...

Page 80: ...g GE Industrial Systems EV200LX SUPPLEMENT Page 4 of 5 REV 11 2002 Wiring Diagram ...

Page 81: ...0 Percent On Time Motor Amperes Peak IM Maximum Peak IM Minimum Average IM Maximum Average IM Minimum Peak Motor C L Typical Motor Inductance Min Max 30 ONTIME 735 1170 Amps Min Max 50 ONTIME 560 990 Amps Min Max 70 ONTIME 390 810 Amps Average Motor C L Typical Motor Inductance Min Max 30 ONTIME 615 960 Amps Min Max 50 ONTIME 480 870 Amps Min Max 70 ONTIME 347 750 Amps ...

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