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Troubleshooting - Motor Controller
CODE
DESCRIPTION
Main Contactor Did Not
39
Close
41
Throttle Open
42
Throttle Short
47
HPD/Sequencing Fault
73
Stall Detected
Encoder Pulse Count
88
Fault
22
POSSIBLE CAUSE
1.
Main contactor did not close.
2.
Main contactor tips are oxi-
dized, burned, or not making
good contact.
3.
External load on battery pack
(B+ connection terminal) that
prevents battery pack from
charging.
4.
Blown 300 amp fuse.
1.
Throttle wiper voltage too
high.
1.
Throttle wiper voltage too low.
1.
Power switch, seat, and throt-
tle inputs applied in incorrect
sequence.
2.
Faulty wiring, crimps, or
switches at power switch,
seat, or throttle inputs.
1.
Stalled motor.
2.
Motor encoder failure.
3.
Bad crimps or faulty wiring.
4.
Problems with power supply
for the motor encoder.
1.
Encoder Steps parameter
does not match the actual
motor encoder.
SET / CLEAR CONDITIONS
Set: With the main contactor commanded
closed, the battery pack voltage (B+ con-
nection terminal) did not charge to B+.
Clear: Cycle power switch.
Set: Throttle wiper (pin 16) voltage is
higher than the high fault threshold.
Clear: Bring throttle wiper voltage below
the fault threshold.
Set: Throttle wiper (pin 16) voltage is lower
than the low fault threshold.
Clear: Bring throttle wiper voltage above
the fault threshold.
Set: HPD (High Pedal Disable) or
sequencing fault caused by incorrect
sequence of power switch, seat, and throt-
tle inputs.
Clear: Reapply inputs in correct sequence
(neutral throttle, power, seat switch).
Set: No motor encoder movement
detected.
Clear: Cycle power switch.
Set: Detected wrong setting of the Encoder
Steps parameter.
Clear: Cycle power switch.
SOLUTION
1.
Inspect contactor cable and connec-
tors.
2.
Inspect all cables and connectors from
batteries to controller.
3.
Inspect contactor contacts for damage
or corrosion and repair or replace con-
tactor.
4.
Inspect 300 amp fuse and replace if
needed.
1.
Inspect throttle cable insulation and
connectors for damage and repair or
replace where needed.
2.
Replace throttle assembly.
1.
Inspect throttle cable and connectors.
2.
Replace throttle assembly.
1.
Cycle power with no pressure on
Speed Pedals.
2.
If error persists, inspect throttle and
seat switch cables.
3.
Recalibrate the accelerator assembly.
Refer to Accelerator Calibration,
page 14.
4.
Replace throttle assembly.
1.
Reduce load on driver so it can move
with applied throttle.
2.
Inspect encoder/thermistor cable. Ver-
ify motor wires U, V, W are properly
wired.
3.
Replace motor.
4.
Replace controller.
1.
Inspect motor encoder/thermistor
cable.
2.
Replace motor.
3A6623C
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Troubleshooting
