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ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE
Troubleshooting
Page 21-16
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
21
6. Recording the battery pack voltage reading while under load provides a more accurate diagnosis of the
condition of the batteries. When the discharge machine is ON, it places the battery pack under load and
many times can help determine if one or more batteries in the set have failed. Testing battery voltage
while the batteries are not under load will not always indicate the true condition of the batteries. For more
information about the batteries, refer to Section 24 – Batteries: Electric Vehicles.
TEST PROCEDURE 8 – KEY SWITCH AND MCOR LIMIT SWITCH CIRCUIT
See General Warning on page 1-1.
Key Switch and MCOR Limit Switch Circuit Test with the Diagnostic Handset
1. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position
jack stands under the frame crossmember between the spring mount and side stringer, just forward of
each rear wheel.
See WARNING “Lift only one end...” in General Warning on page 1-1.
2. Turn the key switch to the OFF position and place the Forward/Reverse switch in the NEUTRAL position.
3. Connect the handset to the vehicle.
See Plugging the Handset into the Vehicle on page 22-1.
4. Test the key switch.
4.1. Access the Test menu, and select KEY INPUT by using the SCROLL DISPLAY buttons. The hand-
set should indicate OFF when the key switch is in the OFF position.
4.2. While monitoring the handset display screen, turn the key switch to the ON position. The handset
should indicate ON.
4.3. If the handset does not indicate that KEY INPUT is ON when the key switch is in the ON position,
proceed to the following procedure, Key Switch and MCOR Limit Switch Circuit Test without the
Diagnostic Handset. If the key switch functions as described, proceed to the following step.
See fol-
lowing NOTE.
NOTE:
The key switch MUST function properly in order to test the MCOR limit switch with the diagnostic
handset.
5. Test the MCOR limit switch.
5.1. Select FOOT INPUT on the Test menu by using the SCROLL DISPLAY buttons on the handset.
5.2. The handset should indicate that FOOT INPUT is OFF when the accelerator pedal is not pressed,
regardless of the key switch position.
5.3. With the key switch in the ON position, press the accelerator pedal. The handset should indicate
that FOOT INPUT is ON when the accelerator pedal is pressed.
6. If any reading is obtained that is not described in steps 4 and 5, perform the following steps:
6.1. Check the pedal group for proper adjustment.
See Section 5 – Pedal Group Adjustment – Elec-
tric Vehicles.
6.2. Check the wiring of the key switch and MCOR.
See Wiring Diagram on page 21-2.
6.3. Check the continuity of the key switch wires and the MCOR limit switch wires.
7. If the problem was not found, proceed to the following procedure, Key Switch and MCOR Limit Switch
Circuit Test without the Diagnostic Handset on page 21-17.
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