2007 Eagle Electric Golf Car Service Manual
© December 2007
4-4
Section 4 - Troubleshooting
TROUBLESHOOTING SPECIFIC COMPLAINTS
The
fi
rst step in sevicing any electric vehicle that is not operating
Troubleshooting is a matter of investigation and deduction based
on the symptoms and the possible causes. Recording every pos-
sible 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:
Fault code light steady OFF
The controller is not getting the
proper voltage or the controller has
failed internally.
1. Check to make sure the controller has a good battery nega-
tive connection at the B- terminal. Attach the black lead of
the VOM to the B- terminal and attach the red lead to the
battery pack positive post.
On DC volts scale, full battery pack voltage should be
observed. If not, check or replace the connections and cable
between the main battery pack negative post and the con-
troller B- post. If correct voltage is present, disconnect the
16 pin wire connection from the controller. Set main power
switch to ON. Insert the black lead to the B- terminal on the
controller and the red lead to the red #1 wire of the 16 pin
connector. Full voltage should be observed.
2. If voltage is present, reconnect the 16 pin plug connector
to the controller and ensure the wires are fully seated in the
back of the plug. If there is system voltage between B- post
and the #1 pin, and the controller light does not illuminate,
the controller has failed internally and must be replaced.
3. If there is no voltage present between the #1 pin and the
B- terminal, and B- terminal has a good connection to bat-
tery pack negative, the red #1 wire circuit is not energizing
properly. Make the charger positive (red) wire is connected
to the main battery pack positive terminal, then check the
table below.
Fault Code
Condition
Correctiive Action
●
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
IMPORTANT: Always follow troubleshooting guide in exact
sequence as listed. Performing tests out of sequence will
cause inaccurate results and lost time in diagnosing electri-
Vehicle Will Not Move; Forward or Reverse
Before attempting to service a vehicle, complete the pre-service inspection and fully test the batteries as described on the previous
page. Set the vehicle power switch to “ON”. The green status light (Figure 4-1) on the controller will show one of three conditions;
steady off, steady on, or
fl
ashing.
NOTE: In some lighting situations it is diff cult to determine the condition of the fault light. Ensure an accurate reading of the light by
shading it.
VOM Black Lead
VOM Red Lead
Pass
Fail
Correction Action - Check
Main battery
Green charger interlock wire
Full system voltage
Low or no voltage
Charger red lead to battery positive connection.
negative post
Charger output wires for damage
Main battery `
Red wire #15 side of
Full system voltage
Low or no voltage
Red wire #15 connection to green charger interlock wire
negative post
1 amp fuse connector
Red wire #15 for damage
Main battery
Red wire #16 side of
Full system voltage
Low or no voltage
1 amp fuse or fuse connections
negative post
1 amp fuse connector
Main battery
Red wire #28 at
Full system voltage
Low or no voltage
Red wire #18 for damage
negative post
power key switch
Red wire #28 to red wire #16 connection
(at optional low/run connection)
Main battery
Red wire #17 at
Full system voltage
Low or no voltage
Wiring from power key switch for damage/poor connections
negative post
solenoid positive tab
Main battery
Red wire #1 at
Full system voltage
Low or no voltage
Wiring from power key switch for damage/poor connections
negative post
16 pin connector
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