Troubleshooting Guide 1 - Club Car Carryall 500 2019 Maintenance And Service Manual

12
Troubleshooting

TROUBLESHOOTING GUIDE 1

The following troubleshooting guide is intended for use with an CDT handset. For CDT operating instructions, refer
to the CDT 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
Page 12-6 2019 Carryall 500 and 700 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
ELECTRICAL SYSTEM TROUBLESHOOTING:
IQ PLUS ELECTRIC VEHICLES
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 12 – MCOR Voltage on page 12-24
See Wheel Brake Assemblies Section
Ensure that vehicle is not over-loaded before returning
to operation
Test Procedure 12 – MCOR Voltage on page 12-24
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 13 – Motor Speed Sensor on page 12-26
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 7 – Key Switch and MCOR Limit Switch
Circuit on page 12-20
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 8 – Forward/Reverse Rocker Switch on
page 12-21