ELECTRICAL SYSTEM TROUBLESHOOTING: IQ
PLUS ELECTRIC VEHICLES
Troubleshooting
12
TROUBLESHOOTING GUIDE 1
The following troubleshooting guide is intended for use with an CDT handset. For CDT operating instructions, refer
to the CDT Owner’s Manual.
See following NOTE.
NOTE:
Before troubleshooting the vehicle, check the diagnostic history from the Special Diagnostics Menu. Note
any fault codes.
_
TROUBLESHOOTING GUIDE 1
SYMPTOM
POSSIBLE CAUSES
CORRECTIVE ACTION
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 24-pin connector
at speed controller or broken wire
Repair and/or connect the 24-pin connector to the speed
controller
Monitor Menu – THROTTLE % value
does not increase as the accelerator
pedal is pressed or Diagnostic Menu –
THROTTLE FAULT 1 fault code
Failed MCOR
Test Procedure 12 – MCOR Voltage on page 12-27
Over-adjusted brakes
See Wheel Brake Assemblies Section
Monitor Menu – HEATSINK °C
indicates that temperature is above
85 °C (145 °F) or Diagnostic Menu –
THERMAL CUTBACK fault code
Vehicle is over-loaded
Ensure that vehicle is not over-loaded before returning
to operation
Failed MCOR
Test Procedure 12 – MCOR Voltage on page 12-27
Monitor Menu – ARM PWM value does
not reach 100% when vehicle is at full
speed
Improper pedal group adjustment
See Accelerator and Brake Pedal Group Section
Loose or disconnected motor speed
sensor or broken wire
Repair and/or connect the three-pin connector to the
motor speed sensor
Loose or disconnected 24-pin connector
at speed controller or broken wire
Repair and/or connect the 24-pin connector to the speed
controller
Monitor Menu – SPEED PULSES menu
item indicates that speed pulses are
OFF when the vehicle is in motion or
Diagnostic Menu – SPEED SENSOR
fault code
Failed motor speed sensor or failed
magnet
Test Procedure 13 – Motor Speed Sensor on page 12-29
Loose or disconnected two-pin connector
at the MCOR or broken wire
Repair and/or connect the two-pin connector to the MCOR
Loose or disconnected 24-pin connector
at speed controller or broken wire
Repair and/or connect the 24-pin connector to the speed
controller
Monitor Menu – FOOT INPUT menu
item indicates that the MCOR internal
limit switch is always ON or always
OFF.
Failed MCOR limit switch
Test Procedure 7 – Key Switch and MCOR Limit Switch
Loose or disconnected Forward/Reverse
rocker switch (quick disconnect terminals)
or broken wire
Repair and/or connect the quick disconnect terminals to
the Forward/Reverse switch
Loose or disconnected Forward/Reverse
rocker switch (three-pin connector) or
broken wire
Repair and/or connect the three-pin connector from the
Forward/Reverse switch to the wire harness
Loose or disconnected 24-pin connector
at speed controller or broken wire
Repair and/or connect the 24-pin connector to the speed
controller
Monitor Menu – FORWARD INPUT
and/or REVERSE INPUT does
not indicate the correct reading or
Diagnostic Menu – PROC/WIRING fault
code
Failed Forward/Reverse rocker switch
Test Procedure 8 – Forward/Reverse Rocker Switch on
TABLE CONTINUED ON NEXT PAGE
2017 Carryall 500 and 700 Maintenance and Service Manual
Page 12-9
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