Troubleshooting Diagrams; 1206Hb-5201 Controller Faults And Troubleshooting - Cushman SHUTTLE 4X Technician's Repair And Service Manual

ELECTRONIC SPEED CONTROL - TCT
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B

TROUBLESHOOTING DIAGRAMS

The following diagrams will assist in servicing the vehicle. By utilizing the diagnostic mode Fault Codes, considerable
time will be saved in determining the probable vehicle operating malfunction. The vehicle controller wiring diagram is
included for your convenience in tracing the electrical wiring.

1206HB-5201 Controller Faults and Troubleshooting

1311 Display
Hardware Failsafe
HW FAILSAFE
Error
Motor Field Winding
FIELD MISSING
open
Armature PWM pulses
M- SHORTED
not detected
Armature Current
CURRENT SENSE
reading at invalid Zero
FAULT
Amps level
Out-of-Range value
Contactor detected as
MAIN DROPOUT 2
opening during Regen
Main Driver FET
MAIN DRIVER OFF
detected as not turning
ON
High Armature Current
MOTOR STALL
when no Speed Pulses
detected
Contactor detected as
MAIN DROPOUT 1
opening during Drive
Main Contactor coil
MAIN COIL OPEN
detected as open
Main Driver FET
MAIN DRIVER ON
detected as ON when
commanded to be OFF
SPEED SENSOR
No speed pulses
FAULT
detected
Main Contactor
MAIN WELDED
detected as stuck
closed
Very high Regen
NEG IA 300
Current
NEG IA 250
High Regen Current
MAIN DRIVER
High Driver Current
OVERCURRENT
Detected
Page F-6
Explanation Tested When
Throttle applied to
cause contactor to
initially close
Contactor closed
Contactor Closed
KSI OFF -> ON,
Continuous
Contactor
commanded to be
closed
Throttle applied to
cause Contactor to
close
Contactor closed
Contactor
commanded to be
closed
Continuous while
KSI ON
Continuous while
KSI ON and
Contactor
commanded to be
open
Contactor closed
Contactor
commanded to be
Open
Continuous
Continuous
Continuous while
Contactor is
commanded to be
closed
Repair and Service Manual
Controller Recover
Response When
1,2,3 KSI cycled
2,8 Condition clears
1,2 Condition clears
KSI OFF-> ON
1,2,3 when condition
cleared
3,9 Throttle reapplied
3,8 Condition clears
Speed Pulses
6
appear
3,9 Throttle reapplied
3 Condition clears
4 Condition clears
4 Condition clears
Contactor
commanded to
4
Open and does
Open
No Action Throttle reapplied 1. High Regen Current
No Action Throttle reapplied 2. High Regen Current
No Action Throttle reapplied
Possible Cause
1. Controller defective
2. Controller power cables mis-wired
1. Field Winding or its connection
open
1. Controller defective
2. Power cables shorted
1. Controller defective
2. Excessive Plug Current detected
1. Contactor opened
2. Contactor coil or wiring opened
1. Controller defective
1. Motor is stalled
2. Defective speed sensor or wiring
1. Contactor opened
2. Contactor coil or wiring opened
1. Contactor coil or wiring open
1. Controller defective
2. Pin 12 short to ground
1.Defective or missing speed sensor
2. Open speed sensor wiring
1. Welded Contactor
1. Main Contactor coil or wiring
shorted
2. Electrical Noise