Repair and Service Manual
Page O-21
TROUBLESHOOTING & DIAGNOSTICS
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
25108
Brake Sensor Error
Brake position sensor input is
out of range, there are three
conditions which can cause
this error.
1. Low sensor voltage, less
than 0.35 volts.
2. High sensor voltage, greater
than 4.8 volts.
3. Sensor voltage greater than
0.85 volts when brake switch
closes.
1. Verify that the 5 volt out put range is 5 ±0.1
volts.
2. Turn key switch to ’N’ and check that the
accelerator pedal is in the upright position.
3. Verify that accelerator pedal arm is in con-
tact with the rubber bumper, if not in contact
with bumper see
ACTION 1
.
4. Verify the throttle sensor voltage is
between 0.35 volts and 4.8 volts. If not in
range see
ACTION 2
.
5. Verify the throttle sensor voltage is less
than or equal to 0.85 volts when throttle
switch closes. If greater than 0.85 volts see
ACTION 3
.
6. Verify other 5 volt supply devices; motor
encoder, resistor module and brake sensor.
1. Remove obstruction.
2. Replace throttle sensor.
3. Replace throttle switch.
4. Repair or replace bad
device.
33024
CAN Timeout
1. This error occurs when the
controller and the handled
devices stop communicating.
1. Check for a loose handheld connection or
a damaged handheld. Replace the CAN Bus
plug (run plug).
1. Cycle the key switch
(turn it off then back on).
2. Depress accelerator
pedal, release and
depress again.
Warning Drive Fault
1. Indicates the current error is
the result of a condition internal
to the controller. The message
can appear in combination with
one of the above error mes-
sages.
1. Trouble shoot according to the controller
error message displayed.
1. Replace motor control-
ler
Warning DC Bus Low
DC Bus voltage is less than 24
volts.
1. Verify that all battery wires are securely
fastened and have less than 0.1 ohms resis-
tance between wire terminal and battery
post.
2. Check the battery voltage across all 4 bat-
teries, voltage should read 42 VDC
MINI-
MUM
.
3. Check voltage across solenoid contacts. If
more than 3 VDC but less than 24 VDC pro-
ceed to step 3, if it does not fall in this range
follow
ACTION 3
.
4. Verify power resistor ohm reading is
between 0.2 and 0.5 ohms.
1. Tighten or replace loose
or high resistance power
wire connections.
2. Replace power resistor.
3. Replace solenoid.
4. If error continues,
replace the controller.
Warning DC Bus High
Controller DC Bus voltage is
greater than 67 volts.
1. Verify that all battery wires are securely
fastened and have less than 0.1 ohms resis-
tance between wire terminal and battery
post.
2. Check the battery voltage across all 4 bat-
teries, voltage should read 63 VDC
MAXI-
MUM
.
3. Check voltage across solenoid contacts. If
more than 3 VDC but less than 24 VDC pro-
ceed to step 3, if it does not fall in this range
follow
ACTION 3
.
1. Tighten or replace loose
or high resistance power
wire connections.
2. Replace power resistor.
3. Replace solenoid.
4. If error continues,
replace the controller.
Warning
(Speed-
ometer
code
1004)
BDI Calibration
1. The DC Bus measurement
system is not calibrated.
no diagnostic steps to perform
1. Replace the controller
CODE
DESCRIPTION
POSSIBLE CAUSES
DIAGNOSTIC STEP
ACTION (post diagnos-
tics)
