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GE IC3645SR3R404P2 - User Manual

GE IC3645SR3R404P2
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INSTALLATION AND OPERATION
SX TRANSISTOR CONTROL Page 1
July 1999
SEPARATELY EXCITED (SX) TRANSISTORIZED DUAL MOTOR CONTROLLERS
INSTALLATION AND OPERATION MANUAL
(IC3645SR3R404P2 & IC3645SR3R404P3)
Note: The information contained herein is intended to assist OEM's, Dealers and Users of electric
vehicles in the application, installation and service of GE solid-state controllers. This manual does not
purport to cover all variations in OEM vehicle types. Nor does it provide for every possible contingency to
be met involving vehicle installation, operation or maintenance. For additional information and/or problem
resolution, please refer the matter to the OEM vehicle manufacturer through his normal field service
channels. Do not contact GE directly for this assistance.
Copyright by General Electric Company July 1999
Section 1.0 INTRODUCTION .......................................................................................................... 4
1.1 Motor Characteristics.................................................................................. 4
1.2 Solid-State Reversing.................................................................................. 5
1.3 Flexible System Application ........................................................................ 5
1.4 More Features with Fewer Components........................................................ 5
Section 2.0 FEATURES OF SX FAMILY OF MOTOR CONTROLLERS .............................................. 5
2.1 Performance............................................................................................... 5
2.1.1 Oscillator Card Features........................................................................ 5
2.1.1.a Standard Operation......................................................................... 5
2.1.1.b Proportional Operation for Dual Motor Vehicles.................................. 6
2.1.1.c Creep Speed.................................................................................. 6
2.1.1.d Control Acceleration and 1A Time .................................................... 6
2.1.2 Current Limit ........................................................................................ 6
2.1.3 Braking................................................................................................ 7
2.1.3.a Plug Braking .................................................................................. 7
2.1.3.b Regenerative Braking to Zero Speed................................................. 7
2.1.3.c Pedal Position Plug Braking ............................................................ 7
2.1.4 Auxiliary Speed Control......................................................................... 7
2.1.4.a Field Weakening............................................................................. 7
2.1.4.b Speed Limits ................................................................................. 7
2.1.5 Ramp Operation ................................................................................... 7
2.1.5.a Ramp Start .................................................................................... 7
2.1.5.b Anti-Rollback.................................................................................. 7
Table of Contents

Table of Contents

Questions and Answers

  • G
    garzacurtisAug 19, 2025
    Why is my GE IC3645SR3R404P2 not operating and how to check battery?
    • A
      Amanda OwensSep 12, 2025
      If the GE Controller isn't operating, it might be due to a discharged or defective battery. Check the battery for the correct open circuit voltage as shown in the troubleshooting diagram, and charge it if needed. Also, check each battery cell for proper voltage (greater than 1.95 volts). Replace or repair the battery if necessary. It's also possible that the control card adjustment is incorrect; in that case, check Function 15 for proper adjustment for the battery being used.
  • D
    Dr. Charles VillarrealAug 21, 2025
    What to do if GE Controller does not operate when accelerator pedal is depressed?
    • S
      seanhowellAug 21, 2025
      If the GE Controller isn't working, it might be because the accelerator pedal is depressed before closing the forward or reverse directional switch. The status code should disappear when the directional switch is closed or the accelerator pedal is released. Another potential cause is a defective directional switch; check the forward or reverse switch to ensure closure when a direction is selected. Also, inspect for an open circuit between the directional switch(es) and battery positive, or between the directional switch(es) and P4 or P5. Check all control wires and connections to resolve this.
  • D
    Dennis HolmesAug 23, 2025
    Why GE IC3645SR3R404P2 will not operate and how to check seat switch?
    • S
      Samantha LopezAug 23, 2025
      If your GE Controller won't operate, it could be due to a mis-adjusted or defective seat or deadman switch. Check to see that the seat switch closes properly. It could also be due to an open circuit between battery positive and P6. Check for loose connections or broken wires between the seat switch and P6, between the key switch and the battery positive side of the seat switch, and between the seat switch and P2. On vehicles without a seat/deadman switch, check for a loose connection or broken wire from P2 and/or P6.
  • J
    Janet WaltersAug 26, 2025
    How to troubleshoot GE IC3645SR3R404P2 that will not operate due to start switch issues?
    • B
      Blake MontgomeryAug 26, 2025
      If the GE Controller is not operating, it may be due to a defective start switch circuit. Check the start switch to ensure it closes when the accelerator is depressed. Inspect the wiring for open circuits or loose connections from the brake switch to the start switch and from P3 to the start switch. It could also be a defective accelerator switch. Check the accelerator switch potentiometer for proper operation and ohmic value.
  • S
    smithchristopherAug 28, 2025
    What to do if GE IC3645SR3R404P2 Controller will not operate due to thermal cut-back?
    • B
      barrstephanieAug 28, 2025
      If the GE Controller is not operating, it could be due to the control being in thermal cut-back. Allow the control to cool down; the status code should disappear. Alternatively, the control itself may be defective, in which case you should replace the controller unit.
  • J
    Jennifer TannerAug 29, 2025
    Why GE IC3645SR3R404P2 will not operate with a new battery?
    • C
      cassandra41Aug 30, 2025
      If the GE Controller is not operating, it could be due to an incorrectly adjusted control card. Check Function 15 for proper adjustment for the battery in use. Alternatively, the battery may be overcharged or the incorrect battery is in use. Check the battery for the proper open circuit voltage per the table. If the voltage is excessive, check the battery charger for the proper output voltage.
  • A
    Allen WallaceSep 1, 2025
    What to do if GE Controller will not operate and the accelerator input is defective?
    • J
      Joe WilsonSep 1, 2025
      If the GE Controller isn't operating, it might be due to a mis-adjusted or defective accelerator input. Adjust or replace the accelerator unit to ensure that the voltage at P7 is correct. Another possibility is an open wire between potentiometer negative and P8; repair or replace the open wire. Finally, the card itself could be defective, so consider replacing the controller unit.
  • G
    Gregory ThompsonSep 3, 2025
    How to fix GE IC3645SR3R404P2 Controller SRO lockout with forward directional switch?
    • M
      Martha SloanSep 3, 2025
      If the GE Controller will not operate due to Static Return to Off (SRO) lockout, it could be because the forward directional switch is closed on initial start-up. Return the directional switch lever to neutral, and then return the lever to the forward position. It might also be that the forward directional switch is welded closed or mis-adjusted to be held closed; replace or adjust the directional switch to ensure that it opens when the directional switch is returned to neutral. Another cause could be a short circuit between P3 and P4; disconnect the wire from P4 and check for a short circuit between P3 and the wire that was connected to P4. If none of these resolves the issue, the control itself may be defective, and you should replace the controller unit.
  • F
    Frederick HaydenSep 5, 2025
    How to resolve GE IC3645SR3R404P2 Controller SRO lockout with reverse directional switch?
    • T
      tristandunnSep 5, 2025
      If the GE Controller will not operate due to Static Return to Off (SRO) lockout, it could be because the reverse directional switch is closed on initial start-up. Return the directional switch lever to neutral, and then return the lever to the reverse position. It might also be that the reverse directional switch is welded closed or mis-adjusted to be held closed; replace or adjust the directional switch to ensure that it opens when the directional switch is returned to neutral. Another cause could be a short circuit between P3 and P5; disconnect the wire from P5 and check for a short circuit between P3 and the wire that was connected to P5. If none of these resolves the issue, the control itself may be defective, and you should replace the controller unit.
  • A
    Andrew MarshSep 7, 2025
    What to do if GE IC3645SR3R404P2 will not operate because of the brake pedal?
    • L
      lisa55Sep 7, 2025
      If the GE Controller isn't operating, a possible cause is a defective brake potentiometer. Replace the brake potentiometer to resolve this. Another cause could be the brake pedal being depressed while trying to motor; release the brake pedal.

GE IC3645SR3R404P2 Specifications

General IconGeneral
BrandGE
ModelIC3645SR3R404P2
CategoryController
LanguageEnglish

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