5 - 9 ELECTRICAL
GEM Service Manual November 2007
DRIVE AND POWER SYSTEM ERROR CODES (Continued)
Error Code Fault Description Corrective Action
57 Motor controller motor current
sensor input is too low while
running.
First go through the Drive and Power System
Troubleshooting Chart A. If directed back to the Drive and
Power System Error Chart perform the following procedure.
Note: Between each step if the code appears, the code will
need to be cleared. To clear the code turn the key and
Master Disconnect switch (MDS) off for 15 minutes. Make
sure Emergency Brake is on. Turn on MDS and then the key
switch. Did code 57 appear? If it does the motor controller
has failed, which may be caused by a shorted motor.
Replace the controller, remove, and inspect motor for
shorting or brunt windings. If the code 57 does not appear,
check for burnt contactor points. On way is to do a voltage
drop test across the points. There should be no more than a
few mill-volt drop (or tenths of a volt). Next try driving the car
in each mode Reverse, Low and High. Did the code set? If it
did, clear the code. Mark sure the key and the MDS are off.
Remove and insulate the F1, F2, A1, and A2 wires from the
motor. Turn on the MDS, key, and try driving the car in
Reverse, Low, and High. Did the code 57 appear? If no, the
motor is shorted and should be replaced. If the code 57 does
appear the controller has failed because of a shorted motor.
Replace both motor and controller.
64 Control detects that the line driver
input (P2-P17) is less than 12%
battery volts when the key switch is
turned ON.
Open wire to Pin 17.
Shorted line driver transistor.
See Troubleshooting Diagram A.
65 Current limit in the line contactor
coil is exceeded during run mode.
The line contactor will drop out and
the key switch will have to be
recycled to reset the control.
Shorted line contactor coil.
Short between the wires connected to the line contactor coil
(wires between pins 17 and 2 of the motor controller). See
Troubleshooting Diagram A.
If the line contactor coil resistance is correct, replace the
motor controller unit.
66 Field transistor exceeds its current
limit. The line contactor will drop out
and the key switch will have to be
recycled to reset the control.
Shorted field F1 to F2.
F1 or F2 terminals shorted to battery positive (B+) or to
battery negative (B-). See Troubleshooting Diagram B.
Binding line contactor.
Visually inspect tips and clean contactor with a solvent.
Noise.
Confirm that all inductive loads/accessories are suppressed.
Excessive motor and control heating (control is in thermal
cutback).
76 Capacitor voltage is too high during
regenerative braking.
Stop vehicle. Shut off key switch and master disconnect
switch. Wait several minutes turn back on. If code reappears
replace the motor controller.
77 Capacitor voltage too high during
motoring.
Replace the motor controller unit. See Troubleshooting
Diagram C.
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