Club Car 1998 DS, Maintenance And Service Manual Supplement

Page: 26 / 132

ELECTRICAL SYSTEM AND TESTING Test Procedures
Page 11-14 1998/1999 PowerDrive Plus Maintenance and Service Supplement
11
TEST PROCEDURES
Read DANGER and WARNING on page 11-11.
Test Procedure 1 - Battery Pack Voltage
With batteries connected and using a multimeter set to 200 volts DC, place the black lead on battery No. 6 negative post and
place the red lead on battery No. 1 positive post. Record the reading for reference, (this information will be referred to as
full
battery voltage and will be useful when performing other test procedures as well).
The voltage reading must be above 32 volts to activate the solenoid to operate the vehicle. If the reading is below 32 volts,
test and recharge the batteries. The battery charger will not turn on if the battery voltage is below 32 volts. The charger relay
will need to be by-passed to activate the charger.
See WARNING on page 11-11.
Test Procedure 2 - Voltage Output From Onboard Computer
1. With batteries connected and using a multimeter set to 200 volts DC, place black lead on battery No. 6 nega-
tive post and red lead (with insulation probe) on blue onboard computer wire (at a point between the OBC
and the six-pin connector). The reading should be approximately 48-50 volts (full battery voltage). If the read-
ing is zero volts, proceed to step 2. If the reading is 48-50 volts, proceed to Test 3.
See WARNING on page 11-
11.
2. If reading is not 48-50 volts, place insulation probe on blue 18 gauge wire at a point between OBC six-pin con-
nector and main wire harness. If reading is zero volts, check blue wire terminal connectors inside six-pin connec-
tor at OBC six-pin connector. Make sure pins are properly aligned inside housing. Make sure wire colors match.
Figure 11-13 Flow Chart 4 - Vehicle Operates, Does Not Charge
REPAIR OR REPLACE
AS REQUIRED
NO CONTINUITY
NO VOLTAGE
NO VOLTAGE
CHECK VEHICLE
WITH A KNOWN
WORKING CHARGER
OR SEE SECTION 14
Vehicle Operates
Does Not Charge Vehicle Operates
Does Not Charge
CHECK ONBOARD
COMPUTER BLACK
WIRE CIRCUIT
TEST PROCEDURE 11
CHECK ALL WIRE
CONNECTIONS
CHECK OBC GRAY
WIRE CIRCUIT
TEST PROCEDURE 12
CHECK RED WIRE
TERMINAL SOCKET
IN RECEPTACLE
TEST PROCEDURE 13
SEE SECTION
14–BATTERY CHARGER
VEHICLE DOES NOT
CHARGE, RELAY CLICKS,
TRANSFORMER HUMS
VEHICLE
CHARGES
INCORRECT
READING
OK
OK
OK
VEHICLE
DOES NOT CHARGE,
NO RELAY CLICK,
NO TRANSFORMER
HUM
REPLACE
ONBOARD COMPUTER
REPLACE
ONBOARD COMPUTER
OK
REPLACE
ONBOARD COMPUTER
REPLACE FUSE
REPAIR OR REPLACE
AS REQUIRED