Troubleshooting Guide 1 - Club Car DS Villager 4 Maintenance And Service Manual Supplement

ELECTRICAL SYSTEM AND TESTING

TROUBLESHOOTING GUIDE 1

The following troubleshooting guide is intended for use with an IQDM handset. For IQDM operating instruc-
tions, See Section 12 – IQ Display Module (IQDM) Series 2 and IQDM-P Diagnostics. See following
NOTE.
NOTE: Before troubleshooting the vehicle, check the diagnostic history from the Special Diagnostics
Menu. Note any fault codes.
TROUBLESHOOTING GUIDE 1
SYMPTOM
Test Menu – THROTTLE % value does
not increase as the accelerator pedal is
pressed
or
Diagnostic Menu – THROTTLE FAULT 1
fault code
Test Menu – HEATSINK °C indicates
that temperature is above
85 °C (145 °F)
or
Diagnostic Menu – THERMAL
CUTBACK fault code
Test Menu – ARM PWM value does not
reach 100% when vehicle is at full
speed
Test Menu – SPEED PULSES menu
item indicates that speed pulses are
OFF when the vehicle is in motion
or
Diagnostic Menu – SPEED SENSOR
fault code
Test Menu – FOOT INPUT menu item
indicates that the MCOR internal limit
switch is always ON or always OFF.
Test Menu – FORWARD INPUT and/or
REVERSE INPUT does not indicate the
correct reading
or
Diagnostic Menu – PROC/WIRING fault
code
Troubleshooting Guide continued on next page...
POSSIBLE CAUSES
Loose or disconnected three-pin
connector at the MCOR or broken wire
Loose or disconnected 16-pin connector
at speed controller or broken wire
Failed MCOR
Over-adjusted brakes
Vehicle is over-loaded
Failed MCOR
Improper pedal group adjustment
Loose or disconnected motor speed
sensor or broken wire
Loose or disconnected 16-pin connector
at speed controller or broken wire
Failed motor speed sensor
Loose or disconnected two-pin connector
at the MCOR or broken wire
Loose or disconnected 16-pin connector
at speed controller or broken wire
Failed MCOR
Loose or disconnected Forward/Reverse
rocker switch (quick disconnect terminals)
or broken wire
Loose or disconnected Forward/Reverse
rocker switch (three-pin connector) or
broken wire
Loose or disconnected 16-pin connector
at speed controller or broken wire
Failed Forward/Reverse rocker switch
2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement
Troubleshooting
CORRECTIVE ACTION
Repair and/or connect the three-pin
connector to the MCOR
Repair and/or connect the 16-pin
connector to the speed controller
Test Procedure 4 – MCOR Voltage on
page 11-19
Section 6 – Wheel Brake Assemblies in
the appropriate maintenance and service
manual
Ensure that vehicle is not over-loaded
before returning to operation
Test Procedure 4 – MCOR Voltage on
page 11-19
Section 5 – Accelerator and Brake Pedal
Group in the appropriate maintenance and
service manual
Repair and/or connect the three-pin
connector to the motor speed sensor
Repair and/or connect the 16-pin
connector to the speed controller
Test Procedure 13 – Motor Speed Sensor
on page 11-36
Repair and/or connect the two-pin
connector to the MCOR
Repair and/or connect the 16-pin
connector to the speed controller
Test Procedure 8 – Key Switch and
MCOR Limit Switch Circuit on page 11-23
Repair and/or connect the quick
disconnect terminals to the Forward/
Reverse switch
Repair and/or connect the three-pin
connector from the Forward/Reverse
switch to the wire harness
Repair and/or connect the 16-pin
connector to the speed controller
Test Procedure 15 – Forward/Reverse
Rocker Switch on page 11-38
Page 11-11
11