Club Car Carryall 300 2021, Maintenance And Service Manual

Page: 180 / 596

12
Troubleshooting
ELECTRIC VEHICLE - ELECTRICAL SYSTEM
TROUBLESHOOTING
TROUBLESHOOTING GUIDE 2
SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION
Speed sensor disconnected or failed
Test Procedure 12 – Motor Speed Sensor on
page 12-27
Incorrect speed setting
To change the programmed top speed of
the vehicle, an OEM-level CDT handheld
programmer must be used
Wiring – improperly wired
Check vehicle wiring. See Sonic Weld, Diode,
and 10k Ohm Resistor Locations on page
12-4.
Batteries – batteries discharged Charge batteries
MCOR malfunction
Test Procedure 11 – MCOR Voltage on page
12-25
Motor – loose wires
Inspect and tighten all wire connections at the
motor.
Failed motor
Replace motor. See Motor Removal on page
16-4.
Vehicle is over-loaded
Ensure that vehicle is not over-loaded before
returning to operation.
Speed controller failure
Replace speed controller. See Speed
Controller Removal on page 13-7.
Brakes – improperly adjusted Section 6 — Wheel Brake Assemblies
Vehicle runs slowly
Tires – under-inflated or flat tires Section 8 — Wheels and Tires
Vehicle operates but has points in pedal
travel where it does not maintain speed nor
accelerate
MCOR malfunction
Test Procedure 11 – MCOR Voltage on page
12-25
Vehicle reaches top speed before 100% pedal
travel is reached
Speed controller – failed throttle resistor(s)
Replace speed controller. See Speed
Controller Removal on page 13-7.
Wiring – improperly wired
Check vehicle wiring. See Sonic Weld, Diode,
and 10k Ohm Resistor Locations on page
12-4.
Vehicle operates, but motor braking function
does not
Speed sensor disconnected or failed
Test Procedure 12 – Motor Speed Sensor on
page 12-27
Forward/Neutral/Reverse control (FNR) –
improperly wired
Test Procedure 6 – Forward/Neutral/Reverse
control (FNR) on page 12-20
Motor – improperly wired
Check motor wiring. See Sonic Weld, Diode,
and 10k Ohm Resistor Locations on page
12-4.
Vehicle will run in forward, but not in reverse or
will run in reverse but not forward
Speed controller – improperly wired or failed
speed controller FET
Check vehicle wiring. See Sonic Weld, Diode,
and 10k Ohm Resistor Locations on page
12-4.
TABLE CONTINUED ON NEXT PAGE
Page 12-10 2021 Carryall 300 Maintenance and Service Manual