Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 422 / 544

Page 21-30
21A
E
Test Procedure 8 - Key Switch Continuity
1. Turn the key switch to OFF and place the forward and reverse switch in NEUTRAL. Disconnect the bat-
teries. Leave the Z plug connected to the controller.
2. Place the black (-) probe of a multimeter, set to ohms (
Ω
), on the small post of the main solenoid (with
the blue, red, and red/white wires attached) and place the red (+) probe on the large post of the main
solenoid (with 6 gauge yellow wire attached) (Figure 21-27). With the key switch OFF, the reading
should be no continuity. Turn the key switch to ON; the reading should be continuity. If the readings are
correct, the key switch is good. If the readings are not correct, proceed to step 3.
3. Remove the center dash. See Page 20-26.
4. Place the black (-) probe of a multimeter, set to ohms (
Ω
), on the key switch terminal with the green
wire attached, and place the red (+) probe on the key switch terminal with the blue wire attached. With
the key switch OFF, the reading should be no continuity. Turn the key switch to ON; the reading should
be continuity. If the readings are not correct, replace the key switch. If the readings are correct, test
continuity of the key switch wires (Test Procedure 9) (Figure 21-28).
Test Procedure 9 - Key Switch Wire Continuity
1. Turn the key switch to OFF and place the forward and reverse switch in NEUTRAL. Disconnect the bat-
teries. Leave the Z plug connected to the controller.
2. Remove the center dash. See Page 20-26.
3. Place the black (-) probe of a multimeter, set to ohms (
Ω
), on the large post of the main solenoid (with
the 6 gauge red wire attached), and place the red (+) probe on the key switch terminal with the green
wire attached (Figure 21-29). The reading should be continuity. If the reading is incorrect, repair or
replace the 18 gauge green wire from the solenoid to the key switch.
4. Place the black (-) probe of a multimeter, set to ohms (
Ω
), on the small post of the main solenoid (with
the red, blue, and red/white wires attached), and place the red (+) probe on the key switch terminal with
the blue wire attached (Figure 21-30). The reading should be continuity. If the reading is incorrect,
repair or replace the blue wire from the key switch to the solenoid.
Test Procedure 10 - Voltage from Z4 (Blue/White Wire) to Main Solenoid Coil
1. Turn the key switch to OFF and place the forward and reverse switch in NEUTRAL. Leave the batteries
connected and leave the Z plug connected to the controller.
2. Place the black (-) probe of a multimeter, set to Volts DC, on the negative (-) post of battery No. 6 and
place the red (+) probe on the small post of the main solenoid (with the blue, red, and red/white wires
attached) (Figure 21-31). With the key switch OFF, the reading should be zero (0) volts. Turn the key
switch to ON; the reading should be Full Battery Voltage. If either reading is incorrect, test the key
switch and wires (See Test Procedures 8 and 9).
FIGURE 21-27 FIGURE 21-28
OFF
DC V
DATA HOLD
AC V
AC/DC 500V MAX
250V MAX
SOLENOID
1
2
OFF
DC V
DATA HOLD
AC V
AC/DC 500V MAX
250V MAX
ORANGE/WHITE
BLUE
KEY SWITCH
BLUE
GREEN