ELECTRICAL SYSTEM AND TESTING
Troubleshooting
Page 11-20
2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement
11
NOTE:
The key switch should be placed in the OFF position and left in the OFF position for the duration of
this test.
2. Connect the IQDM to the vehicle.
3. Access the Test menu and select THROTTLE % by using the SCROLL DISPLAY buttons.
4. The IQDM should indicate 0 % with the pedal not pressed. While monitoring the IQDM display screen,
slowly press the accelerator pedal. As the pedal is pressed, the IQDM should indicate a rise from 0 %
(pedal not pressed) to 100 % (pedal fully pressed).
5. If the MCOR does not operate as described in step 4, proceed to MCOR Voltage Test without the IQDM
MCOR Voltage Test without the IQDM 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, Section 10, Page 10-2.
See following NOTE.
NOTE:
2. With the batteries connected, place Tow/Run switch in RUN. Using a multimeter set to 200 volts DC,
place red (+) probe on battery no. 1 positive post and place black (–) probe (with insulation-piercing
probe) on the purple/white wire at a point close to the three-pin connector at the MCOR. The reading
should be approximately 48-50 volts (full battery voltage).
3. If reading is zero volts, check the purple/white wire continuity from the three-pin connector at the MCOR
to the 16-pin connector at the speed controller. Check terminal positions in three-pin connector at the
MCOR and the 16-pin connector. If all of the continuity readings are correct and the connectors are wired
correctly, replace the speed controller.
4. With multimeter set to 20 volts DC, place the black (–) probe on battery no. 6 negative post and the red
(+) probe (with insulation-piercing probe) on the white wire at a point close to the three-pin connector at
the MCOR. The reading should be approximately 4.65 volts.
5. If reading is zero volts, check the white wire continuity from the three-pin connector at the MCOR to the
16-pin connector at the speed controller. Check terminal positions in three-pin connector at the MCOR
and the 16-pin connector. If all of the continuity readings are correct and the connectors are wired cor-
rectly, replace the speed controller.
6. With multimeter set to 20 volts DC, place the black (–) probe on battery no. 6 negative post and the red
(+) probe (with insulation-piercing probe) on the no. 18 yellow wire at a point close to three-pin connector
at the MCOR. The reading should be approximately 0.32 volts with the pedal up. Slowly press the accel-
erator pedal and note the readings on the multimeter. As the pedal is pressed, the reading should
increase until it reaches 4.65 volts when the pedal is fully pressed.
7. If reading does not increase as the pedal is pressed, replace the MCOR.
8. If the reading is not approximately 4.60 volts with the pedal fully pressed, the vehicle will not operate at
rated top speed. Check the MCOR resistance.
8.1. Disconnect the batteries and discharge the controller.
See Disconnecting The Batteries on
8.2. Disconnect the 16-pin connector at the speed controller.
8.3. Set a multimeter to 20k ohms. Connect the red (+) probe of the multimeter to the yellow wire at the
MCOR three-pin connector with an insulation piercing probe. Connect black (–) probe to the purple/