Club Car DS Villager 4, Maintenance And Service Manual

Page: 220 / 510

12
Troubleshooting
ELECTRIC VEHICLE - TROUBLESHOOTING
AND ELECTRICAL SYSTEM
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 16-pin connector at
speed controller or broken wire
Repair and/or connect the 16-pin connector
to the speed controller
Diagnostic Menu – THROTTLE FAULT fault
code
Failed MCOR
Test Procedure 11 – MCOR Voltage on page
12-23
Armature drive FETs (field-effect transistors)
inside speed controller have failed
Replace the speed controller. See Speed
Controller Removal on page 13-12.
Diagnostic Menu – HW FAILSAFE (Hardware
Failsafe) 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 Warnings on page
1-2. 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 13-13.
Speed controller logic malfunction
Disconnect the batteries and allow the
speed controller capacitors to discharge.
See WARNING “To avoid unintentionally
starting...” in General Warnings on page
1-2. Reconnect the batteries and see if the
symptom returns.
Diagnostic Menu – MAIN DRIVER ON or MAIN
DRIVER OFF fault code
Failure of the FET that controls the solenoid
coil
Replace the speed controller. See Speed
Controller Removal on page 13-12.
Diagnostic Menu – MAIN COIL FAULT fault
code or Diagnostic Menu – MAIN DROPOUT
(1 or 2) fault code
Solenoid coil has failed in an open condition
Replace solenoid. See Solenoid Removal on
page 13-13.
Loose or disconnected motor field coil wires at
motor or speed controller or broken wire
Repair and/or connect the field coil wires
Failure of the motor field windings Section 16 — Electric Vehicle - Motor Diagnostic Menu – FIELD MISSING fault code
Failure of the FETs that control field current
Replace the speed controller. See Speed
Controller Removal on page 13-12.
Diagnostic Menu – HPD (high pedal detect)
fault code
Operator error
Train operators to fully remove foot from
accelerator pedal before turning key switch
to the ON position or changing the selected
direction with the Forward/Reverse switch
Batteries require charging
Place batteries on battery charger and allow
them to fully charge
Diagnostic Menu – LOW BATTERY fault code
Improperly maintained or failed batteries Section 14 — Electric Vehicle - Batteries
Diagnostic Menu – MOTOR STALL fault code Operator error
Train operators to use the brake to hold the
vehicle on a hill, rather than holding the vehicle
on a hill using the accelerator pedal
Page 12-8 2020 Precedent,Villager 2 and 4 Maintenance and Service Manual