Club Car Carryall 500 2019 Maintenance And Service Manual page 183

ELECTRICAL SYSTEM TROUBLESHOOTING: IQ
PLUS ELECTRIC VEHICLES
TROUBLESHOOTING GUIDE 1
SYMPTOM
Monitor Menu – MAIN CONT (solenoid)
does not indicate ON when the solenoid
should be activated. or Diagnostic
Menu – MAIN CONT DNC (main
contactor (solenoid) did not close) fault
code
Monitor Menu – KEY INPUT does not
indicate ON when key switch is in the
ON position
Diagnostic Menu – THROTTLE FAULT
1 fault code
Diagnostic Menu – HW FAILSAFE
(Hardware Failsafe) fault code
Diagnostic Menu – MAIN WELDED
(main solenoid contacts welded) fault
code
Diagnostic Menu – MAIN DRIVER ON
or MAIN DRIVER OFF fault code
Diagnostic Menu – MAIN COIL FAULT
fault code or Diagnostic Menu – MAIN
DROPOUT fault code
TABLE CONTINUED ON NEXT PAGE
POSSIBLE CAUSES
Speed controller logic malfunction
Failed controller FET (that powers up
solenoid coil)
Loose, broken, or disconnected wire(s) at
solenoid or B+ speed controller terminal
Loose or disconnected 24-pin connector
at speed controller or broken wire
Failed solenoid
Loose or disconnected wires at key switch
terminals or broken wire
Loose or disconnected 24-pin connector
at speed controller or broken wire
Failed key switch
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
Armature drive FET's (field-effect
transistors) inside speed controller have
failed
Speed controller logic malfunction
Solenoid contacts have failed closed
Speed controller logic malfunction
Failure of the FET that controls the
solenoid coil
Solenoid coil has failed in an open
condition or broken wire to solenoid coil
2019 Carryall 500 and 700 Maintenance and Service Manual
Troubleshooting
CORRECTIVE ACTION
Disconnect the batteries and allow the speed controller
capacitors to discharge. See WARNING "To avoid
unintentionally starting..." in See General Warnings
on page 1-1. Reconnect the batteries and see if the
symptom returns.
Repair and/or connect the loose or disconnected wire(s)
Repair and/or connect the 24-pin connector to the speed
controller
Replace solenoid. See Solenoid Removal on page 13-8.
Repair and/or connect the quick disconnect terminals to
the Forward/Reverse switch
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 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
Replace the speed controller. See Speed Controller
Removal on page 13-9.
Disconnect the batteries and allow the speed controller
capacitors to discharge. See WARNING "To avoid
unintentionally starting..." in See General Warnings
on page 1-1. Reconnect the batteries and see if the
symptom returns.
Replace solenoid. See Solenoid Removal on page 13-8.
Disconnect the batteries and allow the speed controller
capacitors to discharge. See WARNING "To avoid
unintentionally starting..." in See General Warnings
on page 1-1. Reconnect the batteries and see if the
symptom returns.
Replace the speed controller. See Speed Controller
Removal on page 13-9.
Replace solenoid. See Solenoid Removal on page 13-8.
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