A Textron Company RXV/2FIVE HANDHELD DIAGNOSTICS & TROUBLESHOOTING GUIDE NORTH AMERICA: TECHNICAL ASSISTANCE & WARRANTY PHONE: 1-800-774-3946, FAX: 1-800-448-8124 SERVICE PARTS PHONE: 1-888-GET-EZGO (1-888-438-3946), FAX: 1-800-752-6175 INTERNATIONAL: SALES PHONE: 001-706-798-4311, FAX: 001-706-771-4609 -Z-GO, A Textron Company, 1461 Marvin Griffin Road, Augusta, Georgia USA 30906-3852 627348 53216 Rev A 9/13RXV/2FIVE HANDHELD DIAGNOSTICS & TROUBLESHOOTING Road ei of Socton Band tis soeton bofore atiompting any provost. Pay particular attontion to af Notes, Cautions, Dangers and Warnings, “This HOW TO USE THE HANDHELD PROGRAMMER The Curtis handheld Programmer is used for program- ming, testing, troubleshooting, tuning, diagnosing and parameter adjustments for speed controller and auxiliary devices, jandheld requires 2x AA batteries (not included) * Display Seren, Sot Keys ____ Dela ingens Dota Decraase: Key Power, Favoritos, Moray ae Help Keys Fig. 1 Curtis Handheld Programmer E-Z-GO utilizes a ‘Molex to Tyco’ adaptor connected to the power cord to connect to the vehicle diagnostic port provided under the seat. tis programmer port only. If plugged into the wrong port, voltage from other interface cir- cuits may result in permanent damage to the programmer. The main menu appears after the data is uploaded from the controller unit. PRIMARY CONNECTION: 4 PIN TYCO Located under passenger seat + Remove protective water cap + Use both harness adapters + Align white dots on connector + Engage and twist sleeve to secure, a slight snap or click may be heard/felt Diagnostics & Troubleshooting NAVIGATION With these four keys you can scroll up and down, and right and left, within the display. In the Main Menu, you can use the arrow keys to highlight one of the menus; you then open the highlighted menu using the “Select* softkey, Within menus (other than the Main Menu), the left-arrow key Is used to navigate backwards within menus (other than the Main Menu), the right-arrow key is used to navigate forwards—that is, to ‘open highlighted submenus or items. up | LEFT. -RIGHT Down, CHANGING DATA VALUE Press the Data Increase or Data Decrease key to change the value of the parameter, Favorites This key Is an alternate way to bring up the Favorites menu. You can access the Favorites menu by selecting its icon in the Main Menu, or by using the Favorites key. To seta favorite, navigate to the menu desired and select the softkey “add to”, Use the soft key “select” to select "Favorites" and choose the soft key ‘add! and then "finish w PageLeU mma) Ncl esr es TROUBLESHOOTING ead alo Section 8 and his easton bear atempling ary procedure. Pay parteuar tention o al Notices, Cautions, Dangers and Wamiags MAIN MENU DEFINITIONS + _ SYSTEM INFO - The System Info menu opens directly toa detail screen providing information about the motor Controller to which the programmer is connected. + PARAMETERS - This is where you can adjust the settings of the control system's adjustable parameters. + MONITOR Shows vehicle real-time diagnostics + DIAGNOSTICS Shows active and past faults + PROGRAMMING - Through the Programming menu, you can save and restore your parameter settings files (cp files) + FAVORITES - The Favorites menu consists of the custom set of items you have created HHP SETTINGS - This menu allows you to adjust the appearance ofthe screen displays and also several aspects of the handheld programmer's functionality. + _ FILE MANAGER - With File Manager you can create, delete, move, copy, and paste files and folders, + PLOT & LOG: Through the Plot & Lag menu, you can use the Plot program to plot real-time variables, or use the Log program to create a log of varlable values to view later ina spreadsheet program on your PC. FREEDOM MODE ACCESS Toactivate Freedom Made on your vehicle, you will need to purchase the ‘Freedom Passkey" from your au- thorized E-2-GO service dealer or £-2-GO Service Parts Department. Page2 Diagnostics & TroubleshootingRXV/2FIVE HANDHELD DIAGNOSTICS & TROUBLESHOOTING Read al of Section 6 and tis section botoro atempting eny procedure. Pay particular attention to al Notices, Gans and Wangs System Info van 4 : =| Pil Contos Supenior Profile Selec. f a a Parameters [Freedom En. (RV) = lon/O Profiles (RXV) ForwatdSpeed | cel Selection [1 ieverse Speed [3-7 Golf Coastal onward Speed | 10.2148 ccel Selection [1-4 05 “7 3-Golf- Mild His ‘oruard Speed [102148 el Selection 1-4 52 ES “4-Golf-Steep Hills ard 5 102-148 el Selection | -4 i verse Speed [3-7 5: Freedom Mode ‘onward Speed 114.5.1933 Selection [1-4 seSpeed [3-7 [charge Records | Display Charge Record Number *Amp Hours Minutes hes [oo Command Monitor IMepoed Tole [take Command [vapped Brake [Swe 1 (Wet Usaay ich 2 (Not Use) Pada Sich Hw Sich char Brake Liat Soch TV) [Fonwad Switch FReverve Swish Outputs Mair PWM (Contactor) EN, Brake PWM (Brake Col Brake Lights PWM (Br Light Rely Fan BWA (Fan Buzzer PWN (Reverse Alarm) Resistor PWRTTAR stor Activations (OA Diagnostics & Troubleshooting Page3RXV/2FIVE HANDHELD DIAGNOSTICS & TROUBLESHOOTING Road all of Section 8 and tis section bolero attompling any procedure. Pay paicular attention to af Notices, Cautions, Dangers and Warings, ere reer Poe eT bawekitel Battery |Amp Hours : }o-200000_ | {amie BDI - 4 o % Capacitor Voltage (Wats at Be) : Jo-10s - v Keyswitch Varge zs 0-105) V, [Charge Records Disp. Charge Ree | 1-20 = = Amp Hours p:a0953_——|= ‘AmapElr ‘Winutes 1080 = Min | =tles 555. F Miles Motor fotor RPM Eeacs 72000-12060 [= RPM. : for Temperature zi 00-300 | C z [Controller nent (RMS) Al'3 Phases |= (0800) a Amps [Modulation Depth (6 of wall voltage beina used) _|- 0-100 - % {Controller Frequency -300-300 I= HZ [Temperature FE 100-300 = c [Main State _ = o-10 qo E fo o oe [cutbacks Shown in all fo-100_— = feurrent 95 during cutback) [Contuol Temp Cun. 0-100 5 86 lUndewoltsge cut. 10-100. e 6 lOvervoltage Cut. 10-100. % for Tuning fase Speed Capt. [0-65535) = RH Vehicle Wehicie Hourmeter E jo-100009- {= Hs fcolfsinds Counter ____|0-130000___|- : [Timeto Speed 1 (Max Programmed Speed) fo-320 |. Secs lime to Speed 2 (ax Programmed Speed) Secs [lime Between Speeds Secs [Time to Dist (Preset i Software) fk Secs, [lime to Dist 2 (Preset in stare) L los20 Secs [Time to DTS Presetin tare) L __lox20 i Secs {braking Distance Captired (@resetin Software) L lo-toon00 __|- see [Distance Since Stop [Presetin sofware) lo-4000000__|- [Distance Fine FE (o-4000000, = Fault Counters iain Contactor Welded Hr (0255 = jain Contactor Did NotClo.|_ [0-255 imContactor Dropped (0-255 a [Theottie Wiper | [0-256 = z [arabe Winer 0-255 7 z [EEPROM Failure 0.255 a = 1PD/Sequencing Fault 0255 : severe Undervoltage > 0.255, 5 Severe Overvoltage. E 0.255 e indervoltage Cutback (0-255 = ervoltage Cutback 0.255 {Controller Gvertemp Cutba. | 9-255 oa = IContoller Severe Undert e255, a [cor 0-255, o Precharge Falled 0-235 = } ontoller Qvercuftent 0-255; 5 = Current Sensor Fault 0.255 o = (orTemp Hot Cutback — |" 0255 = = [notor Open __ E [0255 : = itor Temp Sensor Fault [0-255 z [encoder Fault E085. fall Detected jo-255 Page 4 Diagnostics & TroubleshootingRXV/2FIVE HANDHELD DIAGNOSTICS & TROUBLESHOOTING ‘Read a of Section 6 and this section boforeallompling any procedure. Pay particu aention toa Notias, Cautions, Dangers and Waaings. rm vr Menu Breen ‘Submenu 2 See Monitor |FaultCounters eM BtakeFalled ToSet__F [Buzzer Oriver OC BurzerDriver OF E (Buzzer Driver On E Brake Ught Over OT Brake Light Col Missing — Brake Light Driver On [Bake Light river Of —— Resistor Diver OCA) Resistor Missing (XV) esstor ever On (@KVY EN Brake Diver OC [Ev Brake Coll Missing EN Brake Driver On [EM Brake Diver [Han briver Oc Main Col Missing Main Driver Mai Diver OF [EM rake Test Fall Directonenor tTncttle Zero Check |= Resistor Diver O4 (OW) — Supervisor Comms FE upervisorWatehdog | [full rat check, Brake Input Supension [Pedal Switch Supervision | row Soh Supervision [charger Input Supervision Fwd Switch Supersion | jeer Such Supervision —|- [Keyswitch Supervision [Encoder superdsion Hrotle Supervision —— [Ean Coll Missing (2FIVE) | [fan Briver Gc GIVE) Fan Diver Of OFWE) Fan Driver On QFVE Fault Counter (Main Contactor Welded Fir Hour Meter Iain ConfactorDid Not Clo] [Maik Contactor Dropped [hottie Wiper E Brake Wipet F [EEPROM Fallure I. HPO Sequencing Fat —|- Severe Undervoltage | fp-100000— |= His ere Qyervaltag. E 9-190000 His Undervaia F o-100000"— |= His [Overvotage Cuthack | o:100000— |= bis [controler Overtemp Ciba. Te-100900— |= Fis {Contin Severe Under. 0-100000_——|= “This ‘Controer severe Overtemp)- (o-100000 [= [is Precharge Falled E o-1000 = Fis] {Controller Overcurrent [> fe-to0900-—— [TFs [Current Sensor Fault__— [> fo-100000——|-— Fis [hdotor Temp Hot Cutback—[- |e-100000- —_— Motor Open E -100000— = His sor Fault fem |uzzer Dr Buzzer Diver Off, Diagnostics & Troubleshooting PagesRXV/2FIVE HANDHELD DIAGNOSTICS & TROUBLESHOOTING Rend aif of Section Band tis section botor attenreting any procedure. Pay particule attention fo al Notices, Cautions, Dargors and Waraings. cad eich) Soe Pry ree) vars Percy a a a Rasua oe —E eee (eae cas Tee a ae Iselin OE ei pecan —E Sa ee i — fees ne ne ee a ions | jupecetiis aro See Or oa fetes cena LN OF aye - : Pee) E pe eee ae esse bre eee apart ee a oo pag nee ee fall eee ipyaae ee SE Coe fos cher eae earn eee foe sees Se lecausiaay ito ava ae a ee Eee E a Ras fou : e " - Programming Restore pf fle fF aH = cS es sc ra en HAPSettings —_(AccessLevel E fDl/Sve/User__[Dealer eee aa i ceateeme + is —Tie = Nr ia ao ores E Ras tes —— et eat E toa eigeuetet ine — E ets —— He Ee Hats: — pis — eae fe a ets —t ae : Naga aaT ofa a Sor ——tok ee E 0 ani ea 2a tee E ee et es E cme ee —— he E aan - Ke E fest Cul cn fate es pute pata Page 6 Diagnostics & Troubleshooting‘Read alo Scction and his section before attompting any procedure. Pay parila atsnion fo al Noises, Cautions, Dangers and Weaning Se) Sree See ct eee scr HHP Settings Model Displays Handheld Model Number [OEM Number ——F Displays OEM Information. Software Version F Displays Hancheld Software Version HH Resource Version — Displays HHP Rosource information |OME Resource Version [= Displays DME Resource information MH Resource Version | Displays MH Resource information a FM Version. E Displays FYI information [HW Version F Displays Handheld Hardware Vartan [Sera Numbar a Displays Handheld Serlal Number > ___lianufactuting Date Displays Handheld Manu Date Code’ [Shows Fles Saved On Internal Memony Shows Files Saved On External Memory Plots Varlables Stored In Plot variable Ut} Log Ee Logs Variables Stored in "Log Variable Lit” Plot Vaiabte List |= View Saved Variable Listfor Plotting [Cog Variable List View Saved Varieble List for Logging Fre Manager — [Fitemmal s0-Card: Plot Flot 09 Diagnostics & TroubleshootingRXV/2FIVE HANDHELD DIAGNOSTICS & TROUBLESHOOTING ‘Read all of Section 8 and this section before allempling any procedure, Pay particular attention fo afl Notices. Cautions and Warnings. brake ight relay curent below 35mA, wien diver commanded OFF No Action 2. Brake Light Relay Shorted to Ground brake vig — |x) [check Orver output lerake Light Driverstuck Audible Aer la-check wing | jorvern LON. ver [Condition cers [5 Replace Contller H Brake light relay currant below 35mA No Action \wnen diver commanded ON fercketight leew) b tncompete rake light cult erate Light Driver does not Audible Aer Is. verify brake ight relay functionality and Jorver of lemon. |@HVE) Condition leas replace ifnecessary. eit is. tsmatch in Analog/Digital value >. check wring lasaxe out lvebicle check brake sensor |suPeRvIsiON Isupervsor fault \Dizaled [Condition lars [4 replace contaller lanaKELIGHTCON rake ightelay|Beeping —_jBrake Nght relay MssiNG —___—_|coilmissing__[t2rive) detected _|s. Voltage atpin 4too low when eriver's OFF rake light relay current detected> 1Amp, I> checkrelay lovercurenton [Brake Ught 2. Check shorted wiring larane isromvencc_relaydiver [Driver ort |kstoyclad _ |a, check brake sensor other faults ae found rake Pedal tage coeovers| linput voltage to active range. 2. Brake pot wiper voltage toa tow (<0.35V) louside active [shutdown and hrotie ro [2 Brake pot wiper voltage too high (> 46) lomamewiren jane Itnrttle _lapplos |x. check podal operation i excessive Jourenton turer ourentdetectod >200mA Ikoverse aurer {timp Home 2. check wiring lsuzzenonvenoc river rwd0nly —_[Ksleyded __[3.checkbuzzer__ h. buzzer eurront <3mA when diver | lcommanded ON 2 incomplete buzer creat ‘reverse buzzer ump Home Verify continuity of reverse buster and lauzzeRoAVEROFF _|doesnottum an|ewdonly _[conditioncleas replace if open _| 4. Buzzer current above 3 mA when Overs lore | 2, aurter shorted to ground Ineverse Buzzer 3. check driver output lbuzzenoavenon __|swckON __[NoAction _|Conditon clears 4, toplae controller I. smatchin swith status 2. check voltage on ignition interlock Should |ctarcenineuT vehicle be av with charger pluggad in. Should be> SUPERVISION, Isupervisor fault [Diabled [Condition clears |16v unplugged Ee Current on Contrller Phase U,V, oF W above 315 Amps 2. check for bad motor wing [contour excessive Motor |Vehide 3, check for mechanical block lovencunsenT_ current Disabled _|estoysled __|4. check forlow output volte 1 Controller temperature > 85C (1857) 2-checchoat sink temp verify mechanical load |controtier a Verify slew operation lcontmowenoviaten [temperature [current [Temperature _|5.Checkheatsinkalrfiow lcuraack. Ini fcutdack _tatisbelow asc, [é.rossibleresistorfaut | Pages Diagnostics & TroubleshootingRXV/2FIVE HANDHELD DIAGNOSTICS & TROUBLESHOOTING ‘Ra al of Socton B and this secton botoreattompng ny procedure. Pay panicle alfontion fo all Noises, Cautions, Dangers and Wemings 2. controller zemperature > 95¢ (203+) Icontraller 2. Check heat sink temp lemperature 3. Verify mechanical load lanove [Temperature fa. verity slow operation IconTROLLERSEvERE maximum vehicle —_ralis below 95c 8. checkheat sink airflow loverremp threshold __|oisabled_Jand KSiyclec!_[6. Possible resistor fault controler temperatace [temperature |1. Contaller temperature <-400 (-22F) [CONTROLLER SEVERE [below minimum ses above aoc [2. verify temp at heatsink [unoeatene ___[threshoid __|NoAction _fandxsi cycled _|5. warm controler if climate is too col. lL current measurement when motor open lexcoeds thresholds Phase current 2. Check motor connections Imeasurement |vehicle |. check motor field for open [CuRRENTSENSOREAULT loffset error _|isabled _|ksteyeled __|4, Replace the conttllerif motor testis ood 1. Forward/Roverse are both high for second Invalid direction|shutdown oirectionin |. check wiring lbecTION caRoR detected [Throttle _|Newtral 5. check dcoction selector ie Failure in 1. Fallure to read EPROM or checksum error reading non- Ksleycled and [detected \votatte EePROM|Controlter |eePROMread [2 Cycle Key switch [EEPROM FAILURE memory Inoperative [successfully _|3, Replace controller if unsuccossful Ishutdown, 1 Voltage on pin Sistow when diver is OFF lemrake + 2. check for open brake circuit shutdown 3. Verify by putting vehicle in tow and try to EM BRAKECOILMISSING JeMBrake coil Throttle + rll (eank Brae) lopen ormissing [Full Brake _|kSleycled ___[ Inspect park brake [shutdown etBrake + la. current detected > 3 Amps lorivercurent |shutdown 2, Dead short in park brake circuit EMBRAKEDAIVEROC —ftoohighwhen [Throttle + 1, check wiring (Park Brake) ldiverisor® |Full rake _|ksieycled 4. Checkebrake driver coll 4. Driver current below 320mA when driver [shutdown commanded OFF lEMBrake + 2. check for open brake circu, Et Brake driver [Shutdown 2. heck park brake lemsaaKepAVEROFF —|doesnot tum fThrottle + |. check voltage output to brake (ear Brako) low Full Brake _fksicycled__|S. Replace controller Shutdown 7 leMerake 1. Driver current above 220A when driver le Brake driver |Shutdown lcommanded OFF EMBRAKEDAIVERON — féoesnot turn [Throttle + b verity output drivar voltage. lark Broke) lor Full rake _|xSicycled __|3. Raplace contoller if faulty Diagnostics & Troubleshooting PagesRXV/2FIVE HANDHELD DIAGNOSTICS & TROUBLESHOOTING Road al of Secon 6 and thie section before attempting any procedure. Pay paricule attention fo all Notices, Cautions and Warnings. fener Possible Cau fom Shutdown Jem Brake failure hottie + EMBRAKEFAILEDTOSET |tostop motor _|shutdown i. wheel rotation exceeds 1/4 revolutions Park Brake) rotation lemarake _|ksteycied _[2. Check for park brake sip IMotor rotation frullBrake+ EMBRAKETESTFAILED [detected during [Shutdown | { ‘Motor rotation exceods 2 revolutions (ParkBrake) —_———fermaraketost_lewsirake _|kSteycied _[2. Check for park brake slp during startup ly scsing lencoder Pulses [shutdown la. sotor pulses missing while diving lon Motors 2. Eneeder supply below 22mA l2yencoder —_|shutdowne la. check encoder ENCODERFAULT laiconnected leverake _|ksteyced __|a. verify wising 1. Motor RPM measurements between Isupervisor supervisor and Main processors mismatch loetection of| 2. Verify encoder Imotor speed |vehice i. verity wring IENCODERSUPERVISION error lbisabied [Condition dears [a Roplace controller 1. Voltage on pin 3isiow when diver Is OFF IFANCOILMISSING —_jFancoilopenor ran coil b. check fan |2FIvECniy) Inissing INonction [detected __[3. chock wring IFAN DRIVEROC [Driver current I. Fan relay current detected > LAmp [Five only) too ih NoAction _[xSteyeled __|2, check forshort in fan circuit 1. Fan velay current below 35 mA when driver lcommanded ON FAN DRIVER OFF Fan driver does I, check viting For complete circuit 2F1ve only) Inottumon _|NoAaion [Condition leas |3. Replace controller a. Fan elay curent above 35 mA when driver |commanded OFF IFAN DRIERON loriver doos 2. Checkfan crcult \2rIve oniy) lunar __|NoAction _|Concition clears [3 Replace controller i. EM Brake Switeh Hi& Brake Input = 100% 2. EM Brake Switch Low & Brake Input <90% [rake timit I. check brake pedal switch lwiteh 4. check for pedal box debris, lnismateh with 5. check pedal operation FULLBRAKECHECK __jorake potinput |Wo Action [Condition clears [6. Replace brake iit switch if defective 1. Mismatch in switch status 12. check operation on hand held lFwoswrrcr venice I. check direction selector wiring lsurenvision __|supervisor aut [osabled _|condition fears |4. heck direction selector switch Tr. Pedal switch detected as dosed on power \p | 12. check forpedal depression at startup |podal switch 3. check for pedal return pedal switch i |shutdown |dotected open |4. Check for sticking pedal switch IHPOVSEQUENCING FAULT Jon power up [Throttle _|for250ms__|5. Replace Throttle switeh it defective Page 10 Diagnostics & TroubleshootingRoad all of Seaton and this section befor KEYSWITCH SUPERVISION. Eport mel vehicle Isupervisor fault [Disabled _ RXV/2FIVE HANDHELD DIAGNOSTICS & TROUBLESHOOTING Jo altempting any procedwe. Pay particular alton tot! Notices condition lears ble Cause 1. Mismatch in AD value 2. cycle key switeh to clear ls. cheek wiring la, check key switeh 5: Replace key switch if defective 6. Replace Controller if unable to clear fault haat CON. MISSING lcontactorceit [vehicle loven or missing |Disabied \coneitian dears hi. Voltage on pin Gis low when drivers OFF 2. check solencid for open primary clt 5. check for open wiring on coll circuit la check col nputvoltage IMAIN'CONTACTOR DID [Main contactor remainsopen|Vehicle A. Capaciter voltage <{KSI voltage -2 volts) juhen contactor dosed 12. Check voltage aeross contactor secondary veut NOTCLOS:__|whenclosed [Disabled _|ksicycled__|3. Replace contactor f=2V drop h. capacitor voltage < (KS voltage -S vols) aiter contactor initially detected as closed 2. Check for battery voltage loss contactor drops 5. check for secondary voltage loss during laincontactor ——|iwhenin Venice loperation [onorpeD loperation [Disabled _|xstcyeled _|4. Replace contactor if river voltage is OK 1. Capacitor voltage within Lvolt of previous Imeasured capacitor voltage when contactor lopenea contactor 2, check secondary contactor terminals for IMAINCONTACTOR —eannotbe —_‘ehile voit iss when key is of |weL08D loponed _Jbisabled__[tSleyeled ___3, Replace contatorifvoltage does not orop 1. Main co current detected >2 Amps {orivercurrent |Vehicle 2 Check for short in contactor circuit [aun DaIvEROC too high lbisabled__|ksteyeled___|3. check forshort in contactorcoll_ 1, Currentbelow 654 when diver Jcommanded ON 2. check wiring at contactor for good voltage. loriver does not [Vehicle 13. Check key switch MAIN DaIVER OFF leu ON. pisabled _|kSteycled __|4. Replace contro! 1. Current driverabove 65 mA when driver lcommanded OFF 2. Check wiring at contactor for good voltage. loriverdoes not |vehide 3. check key switch IMAINDRVERON __fturn OFF loisabled _[kSteycled __[4. Replace controlier aie 1. Single motor phase current meesured as less than 20 Amps while other phase currents IMotor phase [> 100 Amos OR uviorw Vehicle 2. Al phase crrents measured <5 Amps MOTOR OPEN, detected open [pisabiod _|ksteycled __|3- Check or open motor ceulton UV, 6 Diagnostics & Troubleshooting Paget Cains, Daagors and Wamings.RXV/2FIVE HANDHELD DIAGNOSTICS & TROUBLESHOOTING ‘Rood al of Section B and thie satin before attomping any procedure. Pay particular attention fo al Notees, Cautions and Wansings. pact 1. Motor temperature is above the programmed setting (140C) 2. Chack mechanical load Motor 1. Vaify sensor resistance Imotor jtemperature [4 Check for voltage loss / bad connection at IMotortemeHoT temperature {current drops below set |motor fcureack ltoohot [cutback _[point |. Replace motor [Motor lemperature 1. Motor temp sensor reading out of valid IMoror Temp SENSOR {sensor outside ange AULT lactive range _|ump Hore_|Condition clears |2, check temp sensor it i i. Capacitor voltage > 72V, lexcessive ‘current Voltage below _[2. check resistor crit function loveRVOLTAGE CUTBACK voltage cutback _|set point 3. verify extreme dow hill use 1. Mismatch in switch status 12. Check for good voltage atthe pedal switch lPEDAL SWITCH Wweticle I. check wiring SUPERVISION |supervisor fault [oisabled _|coneltion clears |4, Verify YOwith Handheld _| 1, Capacitor voltage below 75% of battery voltage after precharge 2. check battery voltage 3. checkbattery / contactor witing lcontratierdoes |Vehicle Je. Check contactor operation PrectanceeateD —|notprecharge |oisabled _[ksteyded __ |. Replace controller failed [Shutdown Tevotle + 1. current exceeds comparator rip point IRSISTORDAVEROC —Jorivercurent {shutdown 2 verity driver tuneton on han held (exvontny tootigh ——_[evaroke _[xsteycied _|s: Replace controller hs. Resistordrvercurrent below init when Jarier commanded ON FESISTORDAVEROFF — |oriverdoes not {shutdown 2 verity overtemp or overvotage faults (@vONLY) human Imrotte _fksteyded _[3. Replace controller Resistor driver curcent above limit when liver commanded OFF 2 verity tera conaitions resistor cever verity resistorheat Jresstonoaveron [does nottum feontter [é. check onttller command on hand held |exvonun : finoperative fist eyed ESHA eeceadit | h. voltage on bus barislow when drivers | lore [RESISTOR MISSING shutdown check wire to resistor WV ONLY) Iesistormissing|throtte _lkStevded __[3. Checkrosistor ohm range 86 ohms i fs Mismatch in switch statue p. verity operation on hand hele lrevswirce \Vebice lcnock wiring SUPERVISION Isupervisorfaut [oisabled _|Conaltion clears [5 check Direction selector capacitor Voltage > set point + 10Vols 2. check resistor crue function loxcessive (venice fs verity extreme doven hill use ISEVEREOVERVOLTAGE voltage loisabied _frsicyes [4 verityatery voltage Page 12 Diagnostics & TroubleshootingRXV/2FIVE HANDHELD DIAGNOSTICS & TROUBLESHOOTING ead aot Sete ands secon bate aang ony prosdur, Pay parler arto at Notas, Cutons, Danger end Warnings. Ean ft. Voltaye below 20y 2. Check batery voltage 3. check wiring very Low lt. check contactor [SEVERE UNDERVOLTAGE |pattery Voltage Iksteycied __|5. check charger 4 hi. missing pulses [shutdown 2. check for mechanical bind Ivotorstall — |aotore 5. check For high mechanical load condition shutdown I. Verify motor encoder STALL DETECTED. Hetected __fewrake _[ksteycled__|5. ay show motor overcurrent fa. 1. Communication ercar 2. check for HPO fault 3. This may happen after controller sleep [SUPERVSORCOMMS [supervisor faut J Action _ [condition dears Imode [supervisor fault [thisisan 1. Missing watchdog puises internal vehicle 2. cycle the key switch SUPERVISORWATCHDOG controller check [isabled [condition leas [3 Replace the contcler 1. Mismatch in AD value IVehile 2. Verity sensor voltages-% on hand held THROTTLESUPERVISION [Supervisorfautt[psabled___ condition dears [3. check the SV cmeue [Throttle pot wiper voltage tao ow (< 0.35¥) Pedal inpur (26) 2 Throttle pot wiper voltage too high (>4.8V) [voltage is outof shutdown |Voltage recovers|3 Verify sensor operation on hand held THROTTLE WIPER active range [Throttle Is check pedal operation ft. Throttle switch closed and thratle position lsonsor reads 936 land switch do [shutdown 8. Verity sensor operation on hand held FMOTILEZEROCHECK fnetmateh__frivatle [condition cea [check pedal operation 1. Mismatch in switch status 2. Check switeh operation on hand held [Check for brake unlock n "Tow" frow swrnch vehicle 2. chock tow switch SUPERVISION, jSupenisorfaut isabled [condition clears [4 check tow switch wiring [Current [cutback wit reduce vehicle 4. Voltage betow set point (38V) lspeed to 2. check for good charging lamph or 1/2 Check battery condition JUNDERVOLTAGE tow Battery Jotthe preset|Voltage above a. Possible wiring [cueack. [vottage speed __|setpoint(38v) 5. Possible contactor Diagnostics & Troubleshooting Page 13RXV/2FIVE HANDHELD DIAGNOSTICS & TROUBLESHOOTING ‘Read all of Secton 8 and tis soction before sllompting any procedure, Pay poricula altontion to al Notices, Cautions end Warnings Page 14 —Fataaion Tessin Noncion —__fnfomaton nly __snurdownMotr oto bve sabe Shutdown Main Contactor |Main Contactor Open Shutdown EMBrake __|EM Brake Released Shutdown Throttle {Throttleset to 0 ShutdownDrvert (fain Contacto __|oriver Shutdown ShutdownDriverd {Brake Col) Shutdownbrwvers (GrakeLightRelay) [Driver Shutdown ShutdownDrivers (Fan) [Brver Shutdown Shutdownbrivers (Reverse Alam) [Driver Shutuoven Shutdown Drivers __[Braking Resistor Shutdown Full Brake [Brake set to 100% Limp Home ‘Slow Speed Limit : FweOnl [Forward Operation Only Controller operative _|allDrvers OFF.No Operation. [Throttle set to 0. Full Brake, _Vehide Disabled __[EM Brake Released Current Cutback _|De-rating of motorcurrents TP rast ea