Troubleshooting Guide 1 - Club Car Turf 252 2007 Maintenance And Service Manual

ELECTRICAL SYSTEM AND TESTING: ELECTRIC
VEHICLES

TROUBLESHOOTING GUIDE 1

The following troubleshooting guide is intended for use with an IQDM handset. For IQDM operating instructions, refer
to the IQDM Owner's Manual. 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
Monitor Menu – THROTTLE % value
does not increase as the accelerator
pedal is pressed or Diagnostic Menu –
THROTTLE FAULT 1 fault code
Monitor Menu – HEATSINK °C
indicates that temperature is above
85 °C (145 °F) or Diagnostic Menu –
THERMAL CUTBACK fault code
Monitor Menu – ARM PWM value does
not reach 100% when vehicle is at full
speed
Monitor Menu – SPEED PULSES menu
item indicates that speed pulses are
OFF when the vehicle is in motion or
Diagnostic Menu – SPEED SENSOR
fault code
Monitor Menu – FOOT INPUT menu
item indicates that the MCOR internal
limit switch is always ON or always
OFF.
Monitor Menu – FORWARD INPUT
and/or REVERSE INPUT does
not indicate the correct reading or
Diagnostic Menu – PROC/WIRING fault
code
TABLE CONTINUED ON NEXT PAGE
2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual
POSSIBLE CAUSES
Loose or disconnected three-pin connector at the
MCOR or broken wire
Loose or disconnected 24-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 24-pin connector at speed
controller or broken wire
Failed motor speed sensor or failed magnet
Loose or disconnected two-pin connector at the
MCOR or broken wire
Loose or disconnected 24-pin connector at speed
controller or broken wire
Failed MCOR limit switch
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 24-pin connector at speed
controller or broken wire
Failed Forward/Reverse rocker switch
Troubleshooting
CORRECTIVE ACTION
Repair and/or connect the three-pin connector to
the MCOR
Repair and/or connect the 24-pin connector to the
speed controller
Test Procedure 4 – MCOR Voltage on page 22-13
See Wheel Brake Assemblies Section
Ensure that vehicle is not over-loaded before
returning to operation
Test Procedure 4 – MCOR Voltage on page 22-13
See Accelerator and Brake Pedal Group Section
Repair and/or connect the three-pin connector to
the motor speed sensor
Repair and/or connect the 24-pin connector to the
speed controller
Test Procedure 24 – Motor Speed Sensor on page
22-30
Repair and/or connect the two-pin connector to
the MCOR
Repair and/or connect the 24-pin connector to the
speed controller
Test Procedure 9 – Key Switch and MCOR Limit
Switch Circuit on page 22-18
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 24-pin connector to the
speed controller
Test Procedure 26 – Forward/Reverse Rocker
Switch on page 22-33
22
Page 22-5