Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 424 / 544

Page 21-32
21A
E
Test Procedure 11 - Z4 (Blue/White Wire) Continuity
1. Turn the key switch to OFF and place the forward and reverse switch in NEUTRAL. Disconnect the bat-
teries and disconnect the Z plug from the controller.
2. Make sure the blue/white wire is in the Z4 position in the Z plug. Make sure the blue/white wire is con-
nected to the terminal and that the terminal is properly inserted into the Z plug.
3. Place the black (-) probe of a multimeter, set to ohms (
Ω
), on the small post of the main solenoid (with
the blue/white wire attached), and place the red (+) probe in the Z4 connector position in the Z plug
(Figure 21-32). The reading should be continuity. If the reading is incorrect, repair or replace the wire.
Test Procedure 12 - Main Solenoid Large Post Continuity
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. Disconnect the green wire (from the con-
troller) at the A1 terminal on the motor, and tape the disconnected end to prevent an accidental short
circuit.
2. Place the black (-) probe of a multimeter, set to ohms (
Ω
), on the large post of the main solenoid (with
the 6 gauge yellow wire attached), and place the red (+) probe on the large post of the main solenoid
(with the 6 gauge red wire attached) (Figure 21-33). The reading should be no continuity. If the reading
is incorrect, replace the solenoid
3. Turn the key switch to ON. The solenoid should click and the reading should be continuity. If the sole-
noid clicks and the reading is no continuity, replace the solenoid.
4. If there is no solenoid click, check for voltage to the solenoid coil (See Test Procedures 9 and 10).
Test Procedure 13 - On-board Computer By-pass
If test procedures 1 through 12 show proper operation (no malfunction), but the solenoid will not actuate,
then the problem may be in the on-board computer solenoid lock-out circuit. By-pass the computer and test
the solenoid as follows:
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. Locate the yellow wire at the Z12 position on the Z plug. Unplug the bullet connector in the yellow wire
approximately three inches (7.6 cm) from the Z plug.
3. Connect an 18 gauge jumper wire to the female bullet connector on the end of the yellow wire coming
from the Z plug. Connect the other end of the jumper wire to the negative (-) post of battery No. 6 (Fig-
ure 21-34).
4. Turn the key switch to ON. If the solenoid clicks, test the OBC and OBC fuses. If the solenoid does not
click, test the Z4 blue/white wire and the controller.
FIGURE 21-32 FIGURE 21-33
OFF
DC V
DATA HOLD
AC V
AC/DC 500V MAX
250V MAX
Z8 Z9 Z10 Z11 Z12 Z13
Z1 Z2 Z3 Z4 Z5 Z6 Z7
Z14
PLACE RED
PROBE INTO
THE Z4
POSITION
ON THE Z PLUG
SOLENOID
OFF
DC V
DATA HOLD
AC V
AC/DC 500V MAX
250V MAX
SOLENOID