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Guide to troubleshooting procedures. [To use this guide, refer to the specified
Fig. 17
1
Check for power to the controller
TEST
Check voltage at
It should read full voltage for system.
Check voltage at
It should read 1 to 5 volts less than full battery voltage.
2
Check for main contactor operation and KSI
TEST
Check voltage at contactor and at KSI terminal.
Contactor should read full rated voltage, and KSI must be above 8V.
Check voltage across contactor power terminals.
There should be no measurable voltage drop.
3
Check potbox circuitry
TEST
Check resistance at potbox wires while depressing pedal.
Resistance should be between 0–50 ohms with pedal
4500–5500 ohms with pedal
Check for shorts between potbox wires and vehicle frame.
Resistance should be at least 1 megohm.
Check voltage at upper throttle input terminal on controller.
Voltage should be 2.7 volts with pedal
7.0 volts with pedal
4
Check for controller output
TEST
Check voltage output while depressing pedal (B+ to M-).
Voltage should be zero with pedal
with pedal
.
DOWN
Check current in controller's M- (motor field) lead while
depressing pedal.
Current should be high, and motor should turn.
Curtis PMC 1204X/1205X/1209/1221 Manual
B- and
CONTROLLER
BATTERY
if YES
B- and
CONTROLLER
CONTROLLER
if YES
(0–5kΩ throttles)
.
DOWN
if YES
if YES
, and
UP
, ± a few tenths of a volt.
DOWN
, and full battery voltage
UP
if YES
B+ terminals.
1-A, B, C
if NO
B+ terminals.
1-D
if NO
2-A, B, C
if NO
2-D
if YES
3-A
, and
if NO
UP
3-C
if NO
3-E
if NO
4-A, B, C
if NO
4-D, E
if NO
TROUBLESHOOTING & BENCH TESTING
that follow.]
PROCEDURES
Bad, discharged, or miswired
batteries, or corroded
connections.
: contactor is welded.
TOO HIGH
: 250 Ω resistor or
TOO LOW
controller is defective.
Trace flow to locate
problem.
If voltage drop occurs,
contactor is defective.
Defective potbox, broken wires
to potbox, or improper
mechanical operation.
If lower than 1 MΩ, wiring or
potbox is defective.
Terminal area is probably
contaminated with acid or
dirt.
Controller is defective.
If no current, look for open
circuit. If current is high but
motor won't turn, check motor,
wiring & plug diode.
1-C
1-D
D
2-D
2-E
3-B
3-C
3-E, F
4-C
4-F, G, H, I
27
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