E-Z-GO 2Five Electric Service Manual page 182

TROUBLESHOOTING & DIAGNOSTICS
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
CODE DESCRIPTION
5V Supply Low or
20755
High Voltage
Current Sensor Off-
21008
set Calibration Error
Open Drain Outputs
21520
Current High
25106 Direction Error
Throttle Sensor
25105
Error
25107 Brake Current Low
Page O-20
POSSIBLE CAUSES
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.
1.Error detected in controller
current measurement hard-
ware.
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. Occurs only when the
reverse and forward signals
are simultaneously selected
(normally a short condition in
either the key switch or wiring)
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. Open circuit, harness not
connected.
2. Brake failure
Repair and Service Manual
DIAGNOSTIC STEP
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. 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. 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. 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. 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. Check for loose connection or open circuit
in motor brake harness.
ACTION (post diagnos-
tics)
1. Replace wire harness.
2. Replace sensor.
3. Replace encoder.
4. Replace SOC meter.
5. Replace controller.
1. Replace controller.
1. If shorted condition is
found replace shorted
component.
2. Replace controller.
1. Replace key switch.
2. Replace wiring harness.
3. Replace controller.
1. Remove obstruction.
2. Replace throttle sensor.
3. Replace throttle switch.
4. Repair or replace bad
device.
5. Replace controller.
1. Tighten or replace har-
ness.
2. Replace motor brake.
3. Replace controller.