21
PROGRAMMER DIAGNOSTICS
The programmer presents complete diagnostic information in plain language. Faults are displayed in the
Faults menu (see column 2 in the troubleshooting chart), and the status of the controller inputs/outputs is
displayed in the Monitor Menu.
Accessing the Fault History menu provides a list of the faults that have occurred since the fault history file
was last cleared. Checking (and clearing) the fault history file is recommended each time the vehicle is
brought in for maintenance.
The following 4-step process is recommended for diagnosing and troubleshooting an inoperative vehicle:
(1) visually inspect the vehicle for obvious problems; (2) diagnose the problem, using the programmer; (3)
test the circuitry with the programmer; and (4) correct the problem. Repeat the last three steps as
necessary until the vehicle is operational.
Example: A vehicle that does not operate in “forward” is brought in for repair.
Step 1: Examine the vehicle and its wiring for any obvious problems, such as broken wires or loose
connections.
Step 2: Connect the programmer, select the Faults menu, and read the displayed fault information. In this
example, the display shows “No Known Faults,” indicating that the controller has not detected any
problems.
Step 3: Select the Monitor menu, and observe the status of the inputs and outputs in the forward direction.
In this example, the display shows that the forward switch did not close when “forward” was selected, which
means the problem is either in the forward switch or the switch wiring.
Step 4: Check or replace the forward switch and wiring and repeat the test. If the programmer shows the
forward switch closing and the vehicle now drives normally, the problem has been corrected.
TROUBLESHOOTING CHART
LED
CODE
PROGRAMMER
LCD DISPLAY
EXPLANATION POSSIBLE CAUSE
1,1 HW FAILSAFE
Self-test or watchdog
fault.
1. Controller defective.
1,2
THROTTLE FAULT
1
Wiper signal out of
range
1. Throttle input wire open.
2. Throttle input wire shorted to B+ or B-
3. Throttle pot defective.
1,3
SPEED SENSOR
FAULT
No pulses from sensor.
1. Speed sensor not connected.
2. Speed sensor defective.
1,4 HPD
High Pedal Disable
fault.
1. Improper sequence of direction and throttle
inputs.
1,5 MOTOR STALL Motor stall at current.
1. Slope too steep for vehicle weight.
1. Mechanically locked motor.
2. EM brake wiring failure.
3. Speed sensor defective.
To Next Page
Loading...