2010 Gem el xd error codes

Still chewing on this. Here are some additional thoughts.

Speed sensor

I don’t really suspect that I need to replace the magnet, as I don’t get an error code until I hit the pedal.

This was a guess. We might still need to come back to this.
Agreed, I have always associated -82 being more associated with the sensor and not the magnet.

I DO find it odd that rolling the car For/Back 10 feet does not generate enough signal to trigger a number change on the display. (usually it does). Checking the green wire from the sensor might see some movement on a digital meter but difficult to predict.

Note - If you are rolling the wheel with both tires up in the air, then most likely the other wheel is going in the other direction as you are spinning the first wheel. This is the nature of how your gearbox/differential works and more suitable for another thread.
Mentioned here because if the other wheel is spinning, the motor is probably not(or very much). I think you noticed this with your comment here.

I also noted that the motor only spins when there is torque, so once the wheels are spinning steady, the magnet doesn’t spin and I have stop and spin again to get the motor to spin,

If you want to observe this, Have someone hold the other wheel or block in in some way that keeps it from soinning (possibly leave it on the ground?

-11 Pedal Error
I am leaning more towards something is dodgy in this controller.
From what I can tell from your descriptions, the pedal switch is functioning correctly. Even you test on P3 looks normal.

Random thought of the day
Maybe this is a controller input power issue?
Way back in the beginning of this post I had you fully remove the controller lid for inspection. You had it back together before I could get you to clean the internal pad connections for the Pos and Neg cables (they looked a little messy). We might need to make sure these are cleaned later, but for now → make sure these connections on top of the controller are a bit more than snug tight.

A known point of point of failure is sometimes the flippy breaker on the front of the PSDM. Make a small jumper wire and go across the two connection points as a test.

Another point of fail might also be the twin B- wires on the front of the PSDM (right side). Look at them close for any signs of heat(like a melted case where the studs exit below the cable lug and bolt fastens. As a test → Jump across those two studs (momentarily hold a wire across if you want) and see if that gets you past the -11 at pedal press.

Let us not forget the Pack
It might also be a good idea to go though all of your battery connections and look for loose, corroded, fuzzy, melted, rusty, discolored, or otherwise dodgy connections back there.
Clean, Bright and Tight is the rule.

Thanks @AssyRequired. I’m hoping to get a couple hours tomorrow to mess around some more. I have the controller together but not all bolted into the cart so it wouldn’t be too much work to open it and clean those connections.

I did just try jumping the B wires on the right side… nothing changed. All of the large wires on the PSDM look clean to me. I’m not sure what you mean by the flippy breaker on the front of the PSDM though for the other jumper test?

Do you know if the 7.4v steady I was seeing at the speed sensor is what it should be when not moving?

I might also start going through the Drive and Power Systems Troubleshooting Chart and see if I can find any abnormalities unless anybody can think of any more specific testing. I will be ordering a magnet for the speed sensor just to see.

Drive and Power Systems Troubleshooting Chart

That document seems to get people into more trouble than it actually helps.

The flippy breaker is my pet name for that Main Power Disconnect Switch at the bottom of the fuse panel. Flippy breaker is just more fun to write.

Dial up those detective skills.
Remember to check everything suggested. All connections in the battery chain, the fuse that is back there, Even take a good look at the fuse F13 and look inside the fuse holder for mayhem.

Don’t get too distracted with the speed sensor at this time. We need to clear this -11 first.

I think I have now done all of the checks that people have mentioned. I’ve pulled and reconnected just about every wire that I can find. I have a speed sensor magnet coming soon (and now I definitely need it because I took the mine off and damaged the magnet and plastic ring trying to get it back on).

I just did most of the tests in the Drive and Power System Troubleshooting Chart. There were 2 that didn’t seem right.
Step 11 - Fuse 9 to ground was 20v (should be 12?)
Step 11a - PSDM J4 pin C to ground (I used PSDM 72- or bat-) is 30v (should be 12v?)
Step 7 - On the contactor, one post reads 73v, the other reads 75v, to bat- or 72-.

I also dd the accelerator pedal tests in the manual, which are probably okay but were a little off:
-23-pin connector pin 7 at idle was .3, when pedal pressed all the way it only goes to 3v (should be 4v?)
-23-pin connector pin 3 starts at 4.7 and when pedal pressed goes to .07v (should be 0)

@AssyRequired , I have also jumped the 2 B studs and across the main switch. I’m going to double check all of the battery connections today and the connections at the controller to tighten them up.

Do any of those electrical readings above mean anything to anybody?

That’s 3 things.
Step 11 - What are you using for Ground? (should have been frame/chassis/dash brace (see note1)
Step11a - Yes, should have used Frame/chassis/dash brace. (not B-)
Step 7 - This is normal.

Pedal test is fine. Not your issue.

Moving to the next phase. See you PMessages.

Gotcha, testing those to dash frame rail is 13.4 to both.

Thanks, I will PM you and update this thread if we get anywhere.