Troubleshooting
MERGE 10-10
Chapter 10
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Note:
• Never insert the complete probe into the 9-wire plug for fear of poor contact.
2. When Tow/Run switch is turned on RUN and Forward/Reverse switch is on NEUTRAL, the
multimeter should display a 0V DC voltage.
3. Depress the accelerator pedal, the multimeter should display the full battery voltage (about 48V).
4. If multimeter voltage does not change, the following items must be checked:
• Continuity of wires in harness;
• If the continuity is ok, replace the accelerator pedal switch. Refer to “Check Procedure 6—Circuit
check for key switch and accelerator pedal switch”.
Check Procedure 8—Motor speed sensor
Please refer to Chapter 1 “Protection for Electrical Safety”.
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NOTE:
• The following operations must be conducted on a flat surface. To prevent injury or property
loss, make sure that the passage of the electric vehicle is unblocked before moving it.
1. Turn the key switch to OFF and turn Forward/Reverse gear switch to NEUTRAL.
2. Use a multimeter set to 200V DC, connect the red (+) probe to the positive binding post of the
battery and connect the black (-) probe to the Terminal 16 of the 3-wire connector. The voltage
reading should be approximately 0V (the battery is fully charged).
3. Turn Tow/Run switch to RUN, use a multimeter set to 20V DC, connect the black (-) probe to the
negative binding post of the battery pack and connect the red (+) probe to red wire of the 3-wire
connector. The voltage reading should be approximately 12V.
4. If the reading is 0V, check the continuity of red wire of 3-wire connector which connects the
controller and the motor speed sensor. If the continuity is ok, replace the controller.
5. If the voltage reading is correct, continue with the following operations:
5.1 Use a multimeter set to 20V DC, connect the black (-) probe to the negative binding post of the
battery pack and connect the red (+) probe to the terminal of green wire of the 3-wire connector
on the motor speed sensor. The voltage reading should be approximately 4.60-5.00V.
5.2 If the reading is 0V, check the continuity of green wire of 3-wire connector which connects the
controller and the motor speed sensor. If the continuity is ok, replace the controller.
5.3 If the reading is lower than 3.50V, check the wire and plug for continuity and replace the
controller if necessary.
Summary of Contents for 2010 E-Merge
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