General Electric 262E1 Tomberlin Emerge User Manual

: June 17, 2024
: General Electric

Table of Contents

General Electric 262E1 Tomberlin Emerge
INTRODUCTION
CONNECTIONS
Troubleshooting Sequence
Helpful Hints
WARRANTY
References
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General Electric 262E1 Tomberlin Emerge

General-Electric-262E1-Tomberlin-Emerge-PRODCUT

INTRODUCTION

This sheet is provided to aid in the installation of your remanufactured General Electric controller. Upon installation, you may encounter problems that may, or may not, be due to a faulty controller. The following steps must be taken to help diagnose a possible cart fault or faulty controller. An analog or digital volt-ohm meter (VOM) will be needed to perform these checks.

CHECK MOTOR WINDINGS

Set your VOM to RESISTANCE (Ω).
To test the resistance of VOM leads, please touch the meter leads together.
Subtract this measurement from each test below to get your true measurement.
With the motor disconnected, measure A1 to A2. This should measure approximately BETWEEN .2Ω and 2Ω.
With the motor disconnected, measure F1 to F2. This should measure approximately BETWEEN .8Ω and 3Ω.
With your motor disconnected, measure A1 to F1. This should measure OPEN.
With your motor disconnected, measure F1 to the motor case. This should measure greater than 5MΩ.

CHECK MAIN SOLENOID

Disconnect all wires from the main solenoid.
Set your VOM to RESISTANCE (Ω).
Measure the solenoid coil. This should measure 100Ω – 250Ω (depending on the solenoid type).
Connect VOM leads to the main solenoid lugs.
Attach jumpers from the main battery positive and negative to the coil (small terminals).
The meter must jump from infinity to LESS THAN .3Ω.
Remove jumpers and reconnect solenoid wiring from the harness. (If suppression diode is present,

The non-banded side must go to the wire from pin 11 (Pin 17 on 403E1/TB1) on the controller. Be sure to check the diode functionality with VOM before installation. If a pre-charge resister is installed, please remove it. This control is equipped with an internal resistor, and installing one on the solenoid could cause damage to the control)

CHECK THE CART WIRE HARNESS

Check the connectors on the wire harness for corrosion, loose, broken, burnt, or missing pins.
Repair or replace pins as necessary.

IF ANY OF THE ABOVE ITEMS ARE NOT WITHIN THE SPECIFIED RANGES THE CONTROLLER WILL FAIL. THESE ITEMS MUSTGE 262E1, 262/403 TB1 DIAGNOSTICS
It is recommended to replace your solenoid at the time of controller replacement. FSIP now stocks popular replacement White Rodgers solenoids for your convenience.

CONNECTIONS

48V Battery Pack

General-Electric-262E1-Tomberlin-Emerge-FIG-1

Troubleshooting Sequence

Tomberlin Emerge Troubleshooting Sequence

FOR SAFETY, ALWAYS LIFT THE DRIVE WHEELS OFF THE GROUND WHEN TROUBLESHOOTING!

ALL TESTS ARE CONDUCTED WITH A RUN-TOW/MAINTENANCE SWITCH IN THE RUN POSITION AND WITH A GOOD BATTERY PACK VOLTAGE MEASUREMENT. ALSO, THE CONNECTOR MUST BE ATTACHED TO THE CONTROLLER WHEN
MAKING THESE CHECKS. YOU WILL NEED TO ‘BACK PROBE’ THE PINS FROM THE WIRE SIDE OF THE CONNECTOR. USE A PAPERCLIP IF NECESSARY.
Attach voltmeter negative (-) lead to main Battery Negative (-) for the following tests.
Use the following sequence when checking individual pins (don’t skip steps). If you find a fault, do not move on to the next step until the fault is corrected:

Measure the voltage at the main battery positive post (let’s call it Pack Voltage)

Pin 1 Must be equal to Pack Voltage
If not Pack Voltage, check polarity protection diode, wiring, and Fuse for open condition
Pin 6 With Key Switch Off, must equal 0 volts
If not 0 volts, check the wiring and Key Switch for a shorted condition
Pin 6 With Key Switch On, must equal Pack Voltage
If not Pack Voltage, check wiring and Key Switch for an open condition
Pin 2 With PC/Run Switch in Run mode, must equal Pack Voltage
If not 0 volts, check wiring and Pc/Run Switch for an open condition
Pin 4 With F/R Switch in Reverse, must equal 0 volts
If not 0 volts, check wiring and F/R Switch for a shorted condition
Pin 4 With F/R Switch in Forward, must equal Pack Voltage
If not Pack Voltage, check wiring and F/R Switch for an open condition
Pin 5 With F/R Switch in Forward, must equal 0 volts
If not 0 volts, check wiring and F/R Switch for a shorted condition
Pin 5 With F/R Switch in Reverse, must equal Pack Voltage
If not Pack Voltage, check wiring and F/R Switch for an open condition
Pin 3 With Pedal Up, must equal 0 volts
If not 0 volts, check the wiring and Pedal Switch for a shorted condition
Pin 3 With Pedal Down, must equal Pack Voltage
If not Pack Voltage, check the wiring and Pedal Switch for an open condition
Pin 10 With Direction Switch in Neutral, must equal Pack Voltage
If not Pack Voltage, check the wiring and make sure the beeper is present and connected
Pin 10 With Direction Switch in Reverse, must equal approximately 0 volts (and beeper sounds)
If not approximately 0 volts, check the connector and wire terminal for being burnt/corroded. If the terminal is clean, the controller may be defective
Pin 7 With Pedal Up, must be less than .5 volts
If not less than approximately .5 volts, check wiring and ITS assembly connections
Pin 7 With the Pedal Fully Down, must equal approximately 5.0 volts.
If not approximately 5.0 volts, check the wiring and ITS assembly connections
Pin 15 Must equal approximately 11.5 volts
If not approximately 11.5 volts, remove the speed sensor to see if the voltage recovers to 11.5 volts. If it does return to 11.5 volts, replace the speed sensor, if it does not return to 11.5 volts, check the wiring
Pin 16 Must equal approximately 0 volts
If not approximately 0 volts, check the terminal for being burnt/corroded. If the terminal is clean, the controller may be defective.
Pin 14 While slowly turning the drive wheel, must toggle between 0 volts and approximately 4.5 volts
If not toggling, check the wiring and if necessary replace the Speed Sensor and magnet
Pin 11 (Pin 17 on 403E1/TB1) With Pedal Up, must equal approximately pack voltage
If not approximately pack voltage, check the PC/Run Switch, solenoid coil, and wiring for an open condition
Pin 11 (Pin 17 on 403E1/TB1) With Pedal Down, must equal approximately 0 volts
If not approximately 0 volts, check the terminal for being burnt/corroded. If the terminal is clean, the controller may be defective.
Upgrade Note: If upgrading from 262 to 403, pin 11 will need to be moved to pin 17 location

Helpful Hints

DO NOT UNDERESTIMATE THE IMPORTANCE OF MOTOR RESISTANCE CHECKS AND MAIN SOLENOID CHECKS. MANY CART ISSUES ARE CAUSED BY BURNT/DAMAGED BRUSHES THAT WILL BE FOUND AS PART OF THE ARMATURE RESISTANCE CHECK. Also, A SHORT ARMATURE AND FIELD WITHIN THE MOTOR WILL DAMAGE THIS CONTROLLER.

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WARRANTY

WARRANTY WILL BE VOID

If These Steps are Not Performed Before Installing The Control
STEPS TO PERFORM BEFORE CONTROL INSTALLATION

PRE-INSTALLATION INSTRUCTIONS MUST BE FOLLOWED OR THE WARRANTY WILL BE VOID
IMPORTANT: TOMBERLIN EMERGE TROUBLESHOOTING INFORMATION INCLUDED IN THIS PACKET

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