ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE
Troubleshooting
Page 21-6
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
21
Test 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
Speed controller logic malfunction
Disconnect the batteries and allow the
speed controller capacitors to discharge.
See WARNING “To avoid
unintentionally starting...” in General
Warning on page 1-1.
Reconnect the
batteries and see if the symptom returns.
Loose, broken, or disconnected wire(s) at
solenoid or B+ speed controller terminal
Repair and/or connect the loose or
disconnected wire(s)
Loose or disconnected 16-pin connector
at speed controller or broken wire
Repair and/or connect the 16-pin
connector to the speed controller
Failed solenoid
Replace solenoid.
See Solenoid
Removal on page 23-10.
Test Menu – KEY INPUT does not
indicate ON when key switch is in the
ON position
Loose or disconnected wires at key switch
terminals or broken wire
Repair and/or connect the quick
disconnect terminals to the Forward/
Reverse switch
Loose or disconnected 16-pin connector
at speed controller or broken wire
Repair and/or connect the 16-pin
connector to the speed controller
Failed key switch
Test Procedure 8 – Key Switch and
MCOR Limit Switch Circuit on page 21-16
Diagnostic Menu – THROTTLE FAULT 1
fault code
Loose or disconnected three-pin
connector at the MCOR or broken wire
Repair and/or connect the three-pin
connector to the MCOR
Loose or disconnected 16-pin connector
at speed controller or broken wire
Repair and/or connect the 16-pin
connector to the speed controller
Failed MCOR
Test Procedure 4 – MCOR Voltage on
page 21-12
Diagnostic Menu – HW FAILSAFE
(Hardware Failsafe) fault code
Armature drive FET’s (field-effect
transistors) inside speed controller have
failed
Replace the speed controller.
See Speed
Controller Removal, Section 23,
Page 23-13.
Speed controller logic malfunction
Disconnect the batteries and allow the
speed controller capacitors to discharge.
See WARNING “To avoid
unintentionally starting...” in General
Warning on page 1-1.
Reconnect the
batteries and see if the symptom returns.
Diagnostic Menu – MAIN WELDED
(main solenoid contacts welded) fault
code
solenoid contacts have failed closed
Replace solenoid.
See Solenoid
Removal on page 23-10.
Diagnostic Menu – MAIN DRIVER ON or
MAIN DRIVER OFF fault code
Speed controller logic malfunction
Disconnect the batteries and allow the
speed controller capacitors to discharge.
See WARNING “To avoid
unintentionally starting...” in General
Warning on page 1-1.
Reconnect the
batteries and see if the symptom returns.
Failure of the FET that controls the
solenoid coil
Replace the speed controller.
See Speed
Controller Removal, Section 23,
Page 23-13.
Diagnostic Menu – MAIN COIL FAULT
fault code
or
Diagnostic Menu – MAIN DROPOUT
fault code
Solenoid coil has failed in an open
condition
Replace solenoid.
See Solenoid
Removal on page 23-10.
Troubleshooting Guide continued on next page...
TROUBLESHOOTING GUIDE 1
SYMPTOM
POSSIBLE CAUSES
CORRECTIVE ACTION
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