2007 Eagle Electric Golf Car Service Manual
© December 2007
4-9
Section 4 - Troubleshooting
LED Fault Code Diagnostic Guide
The Sevcon Controller Flash Code Diagnostic Guide can be used to get an initial indication of a problem. In some cases, there are
multiple possible causes for a fault in that category. The causes and veri
fi
cation steps for some fault codes related to system input
or circuitry for the drive system are listed. These obvious faults may not require use of the handset or computer interface. In order to
perform complete speci
fi
c fault diagnosis, a Sevcon Controller Customization Utility Handheld Calibrator PN 79001-04, or Computer
Interface 79003-04, may be required. Training is required to use these tools.
25/26
17/18
various
7
8
9
10
11
11
11
23
27
19
20
20
20
22
15
4
5
5
Sevcon Newer (Beta) 633T45303 Controller - 6 Post
Green LED
Possible Fault Condition
Handset
Cause/Test/Failure
Flashes
ID#
0 Flash
(no green LED)
1 Flash
2 Flash
3 Flash
4 Flash
5 Flash
6 Flash
Internal MOSFET/Contactor
Personality (CRC) out of
range
Illegal start condition
MOSFET short circuit
Contactor fault or motor open
circuit
Motor stall fault
Accelerator fault
No power to Pin 1 from Run/Tow or Power Switch. Also see
No
Power To Controller, Troubleshooting Guide page 4-4.
No power to contactor coil connections.
No power from main contactor to controller B+.
Controller connector wiring open circuit.
Controller connector pin not in place.
Dielectric break down at connector (wet/shorted).
Internal controller fault, MOSFET problem. Replacement of controller
may be required.
Incorrect range settings; requires Handset/Computer or replacement
of controller.
The wire harness controller connector pins may develop an open or
intermittent connection which can also result in these faults. Check
pins and crimps.
Seat switch not closed on accelerator depress (when equipped).
Accelerator switch (pedal) needs to be recycled after a direction
change.
Pedal depress when key turned on.
Wiring fault - two directions selected.
Forward/Reverse switch turned on at power up.
Speed switch out of adjustment.
Micro switch not open with pedal up.
External strobe (
fl
asher) light caused fault. Wiring polarity reversed
on
fl
asher (Rovr/IS only).
Armature circuit short detected or other intermittent electrical short
such as brush dust, etc.
Internal controller fault.
Contactor failed or stuck. Bench test contactor.
Main post to battery corroded.
Test switched side of contactor.
Test 24 Volt small terminal coil (verify correct coil voltage).
Motor open circuit or brushes.
Motor stall condition detected.
Input wire disconnected (white/black lead).
Speed (Pot Box) adjustment required.
Pedal depressed at power up (see 2 Flash).
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