Columbia ParCar Expediter EX21-24A, Service Manual

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Section 4 - Troubleshooting
TROUBLESHOOTING WITH THE HANDHELD
CALIBRATOR
1. Connect the handheld calibrator to the vehicle and enter
the “Read-Only” mode (RON). Scroll down by pressing
“Select” button until you reach the “19” menu (location
19.01). The “Test” light on the left side of the calibrator will
illuminate when the “19” menu is selected. This menu
shows the inputs the controller is observing at that time. At
19.01, the calibrator displays the “Accelerator Push” in
percentage.
2. With the Forward / Reverse knob set to Neutral, slowly
press the accelerator pedal. The “Accelerator Push” value
should rise in value from 0-100% smoothly as you press
the pedal. If the value does not change, the controller is not
receiving input from the accelerator control device
(potentiometer or linear accelerator device). Check all
cable and wire connections regarding the accelerator
control device. If the value does rise, but not to 100%,
adjust the accelerator cable attached to the accelerator
device.
3. Next, check the FS1 Switch input by scrolling to the 19.07
location. At rest, the value for the FS1 Switch should read
open, or (3.OP). When the accelerator pedal is pressed,
the value should change to closed, or (3.CL). If the value
fails to close, check the FS1 wiring circuit and test the
switch with a VOM. Check the wiring back to the controller
(Pin 4).
.
4. Check the direction input to the controller. Observe the
value of the “Forward Switch” item at location 19.05 while
turning the direction selection switch to “Forward” and to
“Neutral”. The switch should read open (1.OP) when the
switch is in neutral and closed (1.CL) when in forward. Do
the same in reverse by monitoring the Reverse Switch at
location 19.06 and value. If the switch fails to close in either
direction, check the switch with a VOM and the wiring back
to the controller (Pin 2 for Forward and Pin 3 for Reverse).
5. Check the Seat Switch at location 19.09. For vehicles
equipped with a seat switch, the value should read open
(5.OP) when the operator seat is not occupied, and closed
(5.CL) when the operator seat is occupied. If the switch
fails to close, check the wiring from the B- post of the
controller to the seat switch, test the seat switch with a
VOM, and check the wiring back to the controller (pin 5).
For vehicles without a seat switch, the value should read
closed (5.CL). If the switch does not register as closed,
check the black wire #5 wiring from the B- post of the
controller to controller plug (pin 5).
If the vehicle is receiving the correct inputs and fails to operate,
contact Columbia Tech Support for further assistance.
VEHICLE WILL NOT MOVE; FORWARD OR REVERSE - LED DIAGNOSTIC GUIDE
Green LED Flashes Check/Test
1 Flash
Check all wire connections for good connection and free of corrosion. Call Columbia Technical Support
if problem persists.
2 Flash Perform steps 1 - 5 under Troubleshooting with Handheld Calibrator above.
3 Flash
Check all wire connections. Disconnect all electrical accessories (strobe lights, heaters, etc.) External
or internal wiring faults will cause 3 Flash. Eliminate all “non-controller” sources first. Plug in calibrator
and read location 13.10 fault code for more precise fault cause(s). Call Columbia Technical Support if
problem persists.
4 Flash
Bench test 48 volt main solenoid. Check all wiring. Plug in Calibrator and read location 13.01 for more
precise fault cause(s).
5 Flash
Motor stall fault. Check motor for damage. Plug in Calibrator and read location 13.10 for more precise
fault cause(s).
6 Flash
Accelerator fault. Check all wiring pertaining to the accelerator switch. Perform steps 1, 3 and 4 under
Troubleshooting with Handheld Calibrator above. .
7 Flash
Low or high battery voltage. Check battery voltage with a voltmeter. If battery voltage drops below 32
volts (48 volt system), the controller will shut down. Read pack voltage both stationary and under hard
acceleration if possible. If voltage is good while static, but drops significantly while accelerating, weak
or damaged batteries may be the cause.
8 Flash Over temperature cutout. Call Columbia Technical Support.
9 Flash Out of range. Call Columbia Technical Support.
10 Flash
Bench test 48 volt main solenoid. Check all wiring. Plug in Calibrator and read location 13.01 for more
precise fault cause(s).