Hustler Zeon Electric Zero turn needs help

[ProEV]

Hi,

I have a Hustler Zero Turn Electric mower that has served me well for 10 years mowing 6 acres in Florida (where grass grows year round). I swapped out the lead acids after the first year for a lithium pack made up from Nissan Leaf batteries (14 modules, 6.2 kWhrs, 59 volts). It mows an hour and a half easily and recharges in 3 hours. Connects to house inverter and solar panels to provide back up power during black outs. Only ever replaced tires and blades.

Finally have some sort of intermittent problem. The display shows 04A57, 16A06, 02A16 and then screen goes dead and flashes weakly. The problem occurs while moving or, running the blades, or just sitting with switch on. Always within about a minute.

I located a recent Smartec controller manual. It seems more recent than the unit I have but the errors match. All these errors have to do with CAN communication or a problem with the controller. I followed the recommended controller testing procedure which was resistance test. Remove cables. Multimeter negative lead to controller battery Positive and then other multimeter lead to U, V, and W. On both drive controllers, I got about 22K to 28K on U and V but 2.5K ohms on W on both. The manual says 270K to 330K would be correct with is off by a digit but the main thing is the difference between W and the other leads. I guess the controllers are damaged.

Does anyone know a source for these model controller FZ5190A Smartec AC-0 48/125 PN 53318-P3?

I tried looking for Hustler Zeon with a part number of HUSTLER 602121 - TRACTION CONTROLLER - HUSTLER MOWERS 602121 but no one claims to have in stock.

The wiring is specific to the lawn mower, so trying to replace it with a generic motor controller would be a nightmare.

Thanks for any suggestions.

 

[ProEV]

Found a pair on Ebay with less than 50 hours on them. I installed them and the old errors disappeared. I did get a new error message : 02A62 which is :
Drive handle or pedal not in neutral position, cruise control on, malfunctioning neutral switch, disconnected or shorted connection
If occurs while running, check the connection at the key switch.
Repair by:
Verify pedal/handle position Verify cruise control is off Verify, repair or replace neutral switch connections as needed Replace neutral switch if alarm persists.

Reading the Smartec manual I see that when the controllers are replaced: 15 Follow the steps outlined in the “Accelerator Sensor Calibration” section to calibrate the new traction controller to the accelerator sensors on (Pages 22 or 23).

 

[ProEV]

I looked for Smartec USB tool that is required to recalibrate the controllers but could not find one. I loosened the bolts holding the accelerator sensor on the right side and tilted it a little one way. This turned out to be a mechanical way to zero the sensor and solved the error. The mower is back in operation.