TROUBLESHOOTING AND DIAGNOSTICS
Page O-7
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
B
20755 5V Supply Low or
High Voltage
1. Typically caused by a short
in the 5 volt wire harness.
2. Malfunction in the control-
ler’s 5 volt (sensor) supply.
3. SOC meter (if equipped)
may be shorted.
4. Resistor control module may
be shorted.
1. Check both +5V and 5V GND to chassis,
resistance should be more than 10k ohms, if
less perform
ACTION 1
.
2. Check throttle and brake sensor for a short
condition, if shorted perform
ACTION 2
.
3. Check motor encoder for a short condition,
if shorted perform
ACTION 3
.
4. Check SOC meter (if equipped) for a short
condition, if shorted perform
ACTION 4
.
1. Replace wire harness.
2. Replace sensor.
3. Replace encoder.
4. Replace SOC meter.
5. Replace controller.
21008 Current Sensor Off-
set Calibration Error
1.Error detected in controller
current measurement hard-
ware.
1. Verify that U, V and W motor wires are
securely fastened and have less than 0.1
ohms resistance between wire terminal and
power post.
2.Check resistance between U-V, V-W and
U-W, each should be 0.4 - 0.8 ohms.
1. Replace controller.
21520
Open Drain Outputs
Current High
1. Current in an open drain out-
put (reverse warning alarm,
park brake, resistor control,
solenoid or brake relay) is
more than rated current.
1. Check each output drain device (reverse
warning alarm, park brake, resistor control,
solenoid or brake relay) for a shorted condi-
tion (less than 0.1 ohms) with the key in the
’OFF’ position.
1. If shorted condition is
found replace shorted
component.
2. Replace controller.
25104
Direction Error
1. Occurs only when the
reverse and forward signals
are simultaneously selected
(normally a short condition in
either the key switch or wiring)
1. Remove key switch, with switch in ’FWD’
and check A-C and A-D, either A-C or A-D
when tested should read less than 0.1 ohms,
NOT BOTH.
2. Repeat step 1 with switch in ’REV’, if step
1 or 2 fail see
ACTION 1
.
3. Remove 23 pin connector form controller,
check mating connector to key switch, pin C
and D for a reading of less than 0.1 ohms, if
over 0.1 ohms see
ACTION 2
.
4. If steps 1 - 3 check out good then see
ACTION 3
.
1. Replace key switch.
2. Replace wiring harness.
3. Replace controller.
25105
Throttle Sensor
Error
1. Throttle position sensor has
a low voltage condition, less
than 0.35 volts.
2. Throttle position sensor has
a high voltage condition,
greater than 4.8 volts.
3. Throttle position sensor has
a voltage less than 0.85 volts
when throttle switch closes.
1. Verify that the 5 volt out put range is 5
volts ±0.1 volts.
2. Turn key switch to ’N’ and place 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.
7. If diagnostic steps 1 and 3-6 fail see
ACTION 5
.
1. Remove obstruction.
2. Replace throttle sensor.
3. Replace throttle switch.
4. Repair or replace bad
device.
5. Replace controller.
CODE
DESCRIPTION
POSSIBLE CAUSES
DIAGNOSTIC STEP
ACTION (post diagnos-
tics)
