Page O-8
TROUBLESHOOTING AND DIAGNOSTICS
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
B
25106
Reverse Alarm Test
Failed
1. Reverse warning alarm
failed at startup check. The
controller tests for a completed
reverse warning alarm circuit.
1. Turn key switch to ’OFF’ and unplug 23 pin
connector from controller.
2. Check the reverse warning alarm for a
shorted condition, less than 0.1 ohms, by
measuring between pin 10 and pin 13 with
the Run/Tow switch in the ’TOW’ position. If
test is greater than 0.1 ohms see
ACTION 1
.
3. Turn key switch to ’R’ and verify voltage to
the reverse warning alarm is 48 volts, if not
then see
ACTION 2
.
1. Replace reverse warn-
ing alarm.
2. Replace wiring
3. Replace controller
25107
Mechanical Brake
Failed
1. Parking brake failed to pre-
vent motor from rotating during
the park brake startup test.
NOTE: this fault may occur if
the key switch is turned to
’OFF’ and then to ’ON’ quickly
while the vehicle is moving.
1. Turn key switch to ’OFF’ and try to push
the vehicle, it should NOT move.
2. Unplug the harness from the motor brake.
3. Verify brake coil resistance is 27 ±3 ohms,
if out of range see
ACTION 1
.
4. Verify that friction disk is in alignment, if
not aligned see
ACTION 2
.
5. Turn key switch to ’ON’ and with the ’Run/
Tow’ switch to ’RUN’ and try to push the car.
1. Replace motor brake.
2. Realign the friction disk.
3. Replace the controller.
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
CODE
DESCRIPTION
POSSIBLE CAUSES
DIAGNOSTIC STEP
ACTION (post diagnos-
tics)