Troubleshooting Guide 2 - Club Car Carryall 500 Maintenance And Service Manual

12
Troubleshooting

TROUBLESHOOTING GUIDE 2

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TROUBLESHOOTING GUIDE 2
SYMPTOM
Vehicle does not operate
TABLE CONTINUED ON NEXT PAGE
Page 12-12 2017 Carryall 500 and 700 Maintenance and Service Manual
POSSIBLE CAUSES
Batteries discharged
Improper or poor battery connections
Battery charger is connected to the vehicle –
Solenoid lockout feature has disabled the vehicle
Key switch and MCOR limit switch circuit
Failed key switch
Failed MCOR
Forward/Reverse rocker switch
Solenoid – loose wires
Solenoid – failed coil
Solenoid – failed solenoid diode
Speed controller thermal cutback
24-pin connector at speed controller
High pedal detect
Motor stall
Motor failure
Failed Run/Tow switch
Speed controller failure
ELECTRICAL SYSTEM TROUBLESHOOTING:
IQ PLUS ELECTRIC VEHICLES
CORRECTIVE ACTION
Charge batteries
Check vehicle wiring. See Wiring Diagrams
beginning on page 12-4
Disconnect the battery charger from the vehicle
Check for loose or disconnected wires at key
switch and MCOR
Test Procedure 7 – Key Switch and MCOR Limit
Switch Circuit on page 12-23
Test Procedure 7 – Key Switch and MCOR Limit
Switch Circuit on page 12-23 See also Test
Procedure 12 – MCOR Voltage on page 12-27
Test Procedure 8 – Forward/Reverse Rocker
Switch on page 12-24
Test Procedure 9 – Solenoid Activating Coil on
page 12-25
Test Procedure 9 – Solenoid Activating Coil on
page 12-25
Test Procedure 9 – Solenoid Activating Coil on
page 12-25
Allow controller to cool and ensure that vehicle is
not over-loaded before returning to operation
Check for loose or disconnected wires at the
24-pin connector. See also Test Procedure 15 –
24-Pin Connector on page 12-33.
Cycle accelerator pedal
Cycle accelerator pedal
Section 16 — Motor (Model DA5-4006): Electric
Vehicles
Test Procedure 3 – Run/Tow Switch on page 12-18
Replace speed controller. See Speed Controller
Removal on page 13-9.