2007 Eagle Electric Golf Car Service Manual
© December 2007
4-7
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 switch 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 accelera-
tor control device. If the value does rise, but not to 100%, ad-
just the accelerator cable attached to the accelerator device.
3. Next, check the FS1 Switch input by scrolling to the 19.07 lo-
cation. 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 regis-
ter 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.
1 Flash
2 Flash
3 Flash
4 Flash
5 Flash
6 Flash
7 Flash
8 Flash
9 Flash
10 Flash
VEHICLE WILL NOT MOVE; FORWARD OR REVERSE - LED DIAGNOSTIC GUIDE
Green
LED
Flashes
Check/Test
Check all wire connections for good connection and free of corrosion.
Call Columbia Technical Support if problem persists.
Perform steps 1 - 5 under
Troubleshooting with Handheld Calibrator
above.
Check all wire connections. Disconnect all electrical accessories (strobe lights, heaters, etc.) External or internal
wiring faults will cause controller 3 Flash. Eliminate all “non-controller” sources
fi
rst. Plug in calibrator and read
location 13.10 fault code for more precise fault cause(s).
Call Columbia Technical Support if problem persists.
Bench test 24 volt main solenoid. Check all wiring. Plug in Calibrator and read location 13.01 for more precise
fault cause(s).
Motor stall fault. Check motor for damage. Plug in Calibrator and read location 13.10 for more precise fault
cause(s).
Accelerator fault. Check all wiring pertaining to the accelerator (pot box) switch.
Perform steps 1, 3 and 4 under
Troubleshooting with Handheld Calibrator
above.
Check the Pot box with an analog ohmmeter.
Low or high battery voltage. Check battery voltage with a voltmeter. If battery voltage drops below 15 volts (24
volt system) or 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 signi
fi
cantly while accelerating,
weak or damaged batteries may be the cause.
Over temperature cutout. Call Columbia Technical Support.
Out of range. Call Columbia Technical Support.
Bench test 24 volt main solenoid. Check all wiring. Plug in Calibrator and read location 13.01 for more precise
fault cause(s).
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