Columbia ParCar Expediter EX21-24A, Service Manual

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Section 4 - Troubleshooting
Perform a visual examination of batteries and
connections.
Examine for signs of corrosion and
clean/or replace any affected terminals or cables.
The batteries can be cleaned by hose washing with a standard garden
hose or with a soft bristle brush (ensure battery caps are present and
tight before washing batteries).
Examine the battery hold-down. If the material from
the hold-down has been dissolved by the sulfuric acid
in the batteries, the hold down can act as a drain on
the battery pack.
Replace the hold-down if it appears damaged.
Test each battery with a VOM (volt-ohm meter). With
VOM set to a scale able to read DC volts at up to 100
volts (or greater), check each battery individually, and
test the entire pack together.
Place the VOM probes on the battery positive and negative post of
each battery. Write down the reading from each battery. Each should
contain at least 6.0 volts and no battery should be more than .5 volts
lower than the highest reading. If any battery tests low on charge,
charge the battery individually with an auxiliary charger or the entire
pack with the onboard charger (allow vehicle to charge until the green
charger light is illuminated, indicating full charge. See arrow Figure 41).
If one or more batteries still test low, the battery should be tested
individually and replaced as necessary.
NOTE: It is recommended that all batteries in a system be changed
together to ensure the batteries are the same brand, vintage, and
service life.
Test each battery cell with a battery hydrometer.
Any battery or battery cell that tests low should be fully charged and
then rechecked. If the cell continues to test low with a hydrometer, the
battery should be replaced. See note above.
A battery may test good with a voltage or hydrometer
test when no load is being drawn from it. Test using a
battery load tester.
A battery must be able to produce 45 minutes of capacity when tested
at 55 amp draw after a complete recharge cycle. A battery that is not
able to produce this capacity should be replaced. See note above.
Figure 4-1
TROUBLESHOOTING SPECIFIC COMPLAINTS
Troubleshooting is a matter of investigation and deduction based on the symptoms and the possible causes. Recording every
possible solution to every possible cause would be impossible, but this troubleshooting section is designed to assist in solving
issues that may arise in the service life of an electric vehicle.
The main key problems encountered with the vehicle(s) are:
▪
Vehicle will not move; forward or reverse
▪
Vehicle operates slowly
▪
Vehicle drives in forward or reverse only
▪
Vehicle drives but operation is jerky or inconsistent
▪
Vehicle power cuts out
NOTICE: Always follow troubleshooting guide in exact sequence as listed. Performing tests out of sequence will cause
inaccurate results and lost time in diagnosing electrical system problems-
TROUBLESHOOTING WITH PCPAK
With the vehicle power system off, connect the PCPak (computer diagnostic utility) and then turn the vehicle power on.