Troubleshooting Diagrams; 1206Hb-5201 Controller Faults And Troubleshooting - E-Z-GO TXT 48V Repair And Service Manual

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

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 Explanation
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 E-6
Controller
Tested When
Response
Throttle applied to
cause contactor to 1,2,3
initially close
Contactor closed 2,8
Contactor Closed 1,2
KSI OFF -> ON,
1,2,3
Continuous
Contactor
commanded to be 3,9
closed
Throttle applied to
cause Contactor to 3,8
close
Contactor closed 6
Contactor
commanded to be 3,9
closed
Continuous while
3
KSI ON
Continuous while
KSI ON and
Contactor 4
commanded to be
open
Contactor closed 4
Contactor
commanded to be 4
Open
Continuous No Action
Continuous No Action
Continuous while
Contactor is
No Action
commanded to be
closed
Repair and Service Manual
Recover
Possible Cause
When
1. Controller defective
KSI cycled
2. Controller power cables mis-wired
1. Field Winding or its connection
Condition clears
open
1. Controller defective
Condition clears
2. Power cables shorted
KSI OFF-> ON
1. Controller defective
when condition
2. Excessive Plug Current detected
cleared
1. Contactor opened
Throttle reapplied
2. Contactor coil or wiring opened
Condition clears 1. Controller defective
Speed Pulses 1. Motor is stalled
appear 2. Defective speed sensor or wiring
1. Contactor opened
Throttle reapplied
2. Contactor coil or wiring opened
Condition clears 1. Contactor coil or wiring open
1. Controller defective
Condition clears
2. Pin 12 short to ground
1.Defective or missing speed sensor
Condition clears
2. Open speed sensor wiring
Contactor
commanded to
1. Welded Contactor
Open and does
Open
Throttle reapplied 1. High Regen Current
Throttle reapplied 2. High Regen Current
1. Main Contactor coil or wiring
Throttle reapplied shorted
2. Electrical Noise