Ransomes E-Plex II User manual

JACOBSEN

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Service

Manual

E-Plex II

Product Code: 898853, 898854

JACOBSEN

WARNING: If incorrectly used this machine can cause severe injury. Those

who use and maintain this machine should be trained in its proper use,

warned of its dangers and should read the entire manual before attempting to

set up, operate, adjust or service the machine.

GBGB

GB

Part No. 24419G Rev 01(RJ 50 102000)

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INTRODUCTION

CONTROLS

ENGINE

DRIVE CHAIN

BRAKE SYSTEM

STEERING

WHEELS & TYRES

HYDRAULICS

CHASSIS

ELECTRICAL SYSTEM

PREVENTATIVE MAINTENANCE

ATTACHMENTS

OPTIONS

MISCELLANEOUS

NOTES

INDEX

15

1

SECTION 1

INTRODUCTION

Machine Specifications

Traction Drive

Motor: G.E. 48 volt DC, shunt wound, totally enclosed 2.6 kW (at 2300 rpm) directly coupled

to a Cushman 15.67:1 ratio worm gear differential. The motor is controlled by a PMC control-

ler. There is a separately excited motor controller (Microprocessor-based), with a half bridge

design, using a Closed loop speed control system.

Speed

Cutting speed 6.4 km/h maximum. Transport Speed 12 km/h

Reel Drive

0.5hp (0.4KW) 48 Volt direct coupled, permanent magnet DC electric motor. Solid State Reel

Control Unit Current-sensing outputs with overload protection.

Batteries

8 Trojan T 105 with up to 3 hour’s operation on one full charge. Option of T 125 and T 145

batteries.

Controls

Electronic motor speed control; Lestronic II 25-amp self charger, integrated raise/lower pedal;

foot operated on/off mowing switch; manual rocker switch for reel raise/lower, rocker switch

for reel on/off selection; reel and lift actuators have overload protection; headlights; battery

condition meter; hour meter: foot pedal forward/reverse With infinite variable speed; regenera-

tive speed control.

Brakes

15 cm (6”) diameter disc brakes on each wheel, mechanically foot actuated.

Tyres

20 x 10-10, 2 ply 0.68 bar ground pressure.

Steering

380 mm steering wheel with cable to rear wheel requiring 5kg effort on concrete.

2.5 turns lock to lock, available electric power steering < 5% range loss expected.

Lift Lower

48 volt linear actuator (Warner Electric) Adjustable internal limit switches, Independently

selected , manual up down control.

9

SECTION 9

CHASSIS

New Locating

Locating Pin

To Secure In

Work

Locking

Pin Three

Positions

Cutting Units

Quick Detach Units

Cutting Unit Maintenance

The cylinder to Bottom Blade adjustment on the E-Plex is of the utmost importance.

The drag felt on the motor caused by an incorrect adjusted cylinder will greatly reduce the

performance of the machine.

10

10-1

SECTION 10

ELECTRICAL SYSTEM

10A. Repair, Service Tools and Materials ............................................................. 10A-3

10B. Batteries Performance/ Charging/Maintenance........................................... .10B-5

10C. Layout Of Components(Batteries, Traction Motor) ........................................10C-7

Layout Of Components (RCU) .................................................................10C-8

Layout Of Components ( Cutting Unit Motor,Controllers)...........................10C-9

10D. Electrical Circuit Description.....................................................................10D-10

10E. Schematic diagrams..................................................................................10E-14

Master Diagram .................................................................................... 10E-14

Key Switch Off ....................................................................................... 10E-15

Key Switch 1st Position ........................................................................ 10E-16

Manual Lower Switch Depressed .......................................................... 10E-17

Limit Switch Activates ........................................................................... 10E-18

Key Switch Start Position ...................................................................... 10E-19

Run Position Transport Machine ........................................................... 10E-20

Run Position Mow.................................................................................. 10E-21

CentreUnits Lowers ...............................................................................10E-22

Centre Unit Limit Switch ........................................................................ 10E-23

Raise Pedal Depressed........................................................................ 10E-24

Centre Unit Raises ................................................................................ 10E-25

Centre Unit Raised ................................................................................ 10E-26

Machine Switched Off............................................................................ 10E-27

10F. Programmer Terms.................................................................................... 10F-28

10G. Fault finding - Locating wire connections....................................................10G-30

RCU Controller voltage tests..................................................................10G-31

RCU Actuator Circuit testing (limit switches and wiring) .........................10G-34

RCU actuator motor test ........................................................................10G-35

Main Contactor output ...........................................................................10G-36

Main reel contactor/electronic throttle .....................................................10G-37

Mow speed pot testing, seat switch testing ............................................10G-38

Solenoid contactor testing .....................................................................10G-39

Curtis PMC Controller - LED Diagnosis.....................................................10G-40

Trouble shooting chart ...........................................................................10G-41

10A

ELECTRICAL SYSTEM

SECTION 10A. REPAIR, SERVICE TOOLS AND MATERIALS

10A-3

Tools required: Digital Multimeter

Jumper wires

60 amp Ammeter

Battery Tester

Cleaning Materials: Baking soda and water

Water repellent (WD40)

Other service items: Electrical insulation compound

10B

ELECTRICAL SYSTEM

SECTION 10B. BATTERIES PERFORMANCE CHARGING MAINTENANCE

10B-5

Batteries

8 x 48 Volt battery pack. Trojan T 105 T 125 or T 145 batteries, available with a removable lift out

battery pack.

Minutes @ Minutes @20 Hour Weight

Volts 25 Amps 75 Amps Rate (KGs)

Trojan T-105 6 419 115 217 28.18

Trojan T-125 6 477 132 235 30.00

Trojan T-145 6 530 145 244 32.72

Total battery pack weight = 225.44 kg minimum 261,76 kg maximum

Note: The 20 hr rate is a rate used by the U.S. to calculate battery running time at a particular amp

draw.

Performance /Charging /Maintenance

The battery performance on the E-Plex is greatly affected by the adjustment of the cutting units and

the batteries working performance will be greatly reduced. Specially by dull unsharpened cylinders,

to this end a regular maintenance program should be enforced (see cutting unit section). Tyre pres-

sures should also be checked regularly.

Before any charging procedure takes place assure that the electrolyte level in the cells, it should be

above the plates. If the electrolyte consumption is excessive it indicates one of the following:

Overcharging

High temperature operation

The battery is at the end of its service life

The battery pack is only as good as the worst battery in the pack, so take regular specific gravity

readings of all batteries. If low readings are found on any one battery try charging the battery out of

the pack and check condition. A normal reading will be between 1.250 and 1.280. If low readings

are found across the pack check that the charger is operating correctly.

Avoid the top up charge, traction battery’s life is measured in cycles every time you charge the

battery removes a cycle from its life. Remember batteries supplied are not pre-conditioned so a

period of conditioning is required.

Do not allow discharged batteries to stored for an extended period of time. Check Chart below:

Below 4 degrees C Charge every 6 months

Between 4 and 15 degrees C Charge every 2 months

Above 15 degrees C Charge once a month

It cannot be stressed enough the importance of a proper battery maintenance program especially on

Demo units.

10C

ELECTRICAL SYSTEM

SECTION 10C. LAYOUT OF COMPONENTS

10C-7

Electric’s

Eight Six Volt Trojan T105 Batteries as Standard, Showing lift out point for quick change

of pack

Traction Motor

48 Volt D.C. Motor showing sensor for speed control.

ELECTRICAL SYSTEM

SECTION 10C. LAYOUT OF COMPONENTS

10C-8

10C

ELECTRICAL SYSTEM

SECTION 10C. LAYOUT OF COMPONENTS

10C-9

Cutting Unit Motor

0.5 H.P Cutting Unit Motor

Controllers

Motor

0.5hp

Reel Control

Unit

SECTION 10D. ELECTRICAL CIRCUITS DESCRIPTION

ELECTRICAL SYSTEM

10D-11

10D

ELECTRICAL CIRCUITS

(Use wiring diagrams with the following descriptions)

General Description

Power for the E-Plex II is supplied by eight six-volt traction batteries. The 48V DC circuit has two

separate controllers, the RCU (Reel Control Unit) for the cutting, lift and lower circuits and the SCU

(Speed Control Unit) for the traction circuit.

The traction motor is a 48V DC shunt wound motor, a speed control chip and sensor allow the

machine to be driven in the same way as hydraulic powered units.

The cutting unit motors are 48V DC motors. The cutting unit motors are protected from damage by

potted circuit breakers.

The48V DC worm drive actuators serve as lift arms, limit switches ensure that the arms can float, lift

and lower correctly.

System Description

Stage One Key Position

The machine has a Service Position this allows for service work to be carried out on the machine

without drive to the traction system.

Power is supplied to the key switch through a 12.5A circuit breaker. In the first key position the

connectors ACC and IGN are connected.

Power is supplied to the control switches. Individual function of the switches is described below.

Manual Lift/Lower

Power is fed to the manual lift/lower switch from IGN position on the key switch. To select lift the

operator pushes the switch this sends an impulse to the RCU on the lift side. Depending on the

position of the three enable switches, one two or three units can be lifted.

With the switch in the enable position an impulse is sent to the RCU. With the actuator in the lowered

position the down limit switch closed. An impulse to the RCU allows the actuator to be raised.

When fully raised the (up limit) switch closes which again sends an impulse to the RCU disengaging

the power to the actuator.

The adjustment of the limit switches is important and is covered in Section ———— of this manual.

Note: No Reel Drive is available when in the Service Position.

SECTION 10D. ELECTRICAL CIRCUITS DESCRIPTION

ELECTRICAL SYSTEM

10D-12

Stage 2 Key Position (Start)

To start the machine, the key is turned to the ST (start) position. In order to start the machine the lift/

lower pedal must be in the raised position and the operator must be sat in the seat. If either switch is

not in the correct position the RCU will not allow the machine to start.

A feed is sent from the RCU to the coil of the Traction Contactor, closing the contactor allowing a

connection to B+ on the SCU. Feeds also input the SCU at the interlock and the coil return.

From the ST position a feed is sent to the start position on the RCU which transfers control from the

manual lift/lower switch to the raise/lower foot-pedal. The Green light illuminates indicating that the

machine is ready for operation.

Transport and Mow Speed

With the Transport/Mow switch in the transport position the machine can be driven at the maximum

speed of 12km/h .The electronic throttle connected to the drive pedal sends a signal to the SCU.

The position of the throttle sets a resistance, which is sensed by the SCU, this resistance figure

changes the speed. A more detailed description can be found in the Section on the SCU later in this

manual.

Power is sent to the motor’s armature from the B+ (positive side of battery) position on the SCU.

Within the controller a connection is made from B+ to F1 the motors field coil. Return connections

are made from A2 (armature) F2 (field coil) and B- negative side of battery. These connections set

up the magnetic field, which drives the motor.

A sensor on the motor ‘again in simple terms’ monitors the speed the motor is turning. The SCU

then adjusts the voltage control according to the speed. The SCU works by switching the DC

voltage on and off (mark speed ratio). If an overrun situation occurs for example ‘descending a

slope’ the speed the motor is turning is faster than the SCU outputs are set, in this situation the motor

is turned into a generator by the SCU in a so called regenerative speed, this load slows the motor.

This braking action occurs as long as the outputs do not match the motor speed.

The sensor is a magnet and a chip, which can be found at the front of the motor.

In the mow position the switch on the control panel is switched to the mow position, a signal is sent

from the switch to the SCU. The SCU then senses the position of the mow potentiometer this

changes the resistance figure slowing the motor, by changing the mark speed ratio. At the same time

a signal is sent to the RCU from the drive motor sensor this tells the RCU that the machine is in the

mow position. It is only possible to run the reels when the machine is in the mow position.

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