Club Car 1998 DS, Maintenance And Service Manual Supplement

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ELECTRICAL SYSTEM AND TESTING Test Procedures
1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 11-17
11
5. If the continuity readings are correct, replace the Tow/Run switch.
Test Procedure 7 - Battery Pack Voltage (Under Load)
1. Before proceeding with this test procedure, the batteries must be fully charged. Using a 36 to 48-volt battery
discharge machine (Club Car No. 101831901), connect the positive (+) lead of the discharge machine to bat-
tery No. 1 positive post and connect the negative (-) lead to battery No. 6 negative post. Record reading from
discharge machine.
See WARNING on page 11-11.
2. Record the voltage reading of battery pack while under load, as displayed on the discharge machine (dis-
charge machine is ON).
3. A fully charged set of batteries in good condition should read between 46-49 volts while under load.
4. A reading of 32-46 volts indicates discharged or defective batteries. Each battery should be checked with a
multimeter while under load.
5. A reading of 32 volts or less will not activate discharge machine. Batteries are deeply discharged or defective.
6. Recording the battery pack voltage reading while under load provides a more accurate diagnosis of the con-
dition of the batteries. When the discharge machine is ON, it places the battery pack under load and many
times can help determine if one or more batteries in the set are defective. Testing battery voltage while the
batteries are not under load will not always indicate the true condition of the batteries.
7. If batteries test okay and vehicle runs slow, test the dynamic braking solenoid for proper operation.
8. Drive vehicle approximately 100 ft. with the accelerator pedal half way depressed to the floor. Stop the vehicle
and check the resistor coil on the dynamic braking solenoid by placing hand close to (but not touching) the
coil. If the coil is hot, replace the solenoid.
Test Procedure 8 - Dynamic Braking Solenoid Activating Coil
1. With key switch ON and Forward/Reverse switch in FORWARD, place Tow/Run switch in RUN. Using a multimeter
set to 200 volts DC, place the red lead on battery No. 1 positive post and the black lead on the brown wire at the
dynamic braking solenoid small post. With the accelerator pedal up, the reading should be less than 1 volt. With the
accelerator pedal depressed, the reading should be 48-50 volts (full battery voltage).
See WARNING on page 11-
11.
2. If the reading is not approximately 48 volts when the accelerator pedal is depressed, check the continuity of the
brown wire and check pin 12 in the 23-pin connector (see Test Procedure 10) . If the connector and continuity
readings are correct, replace the controller. If the reading is approximately 48 volts proceed to step 3.
3. Using a multimeter set to 200 volts DC, place black lead on battery No. 6 negative post and place red lead on the
orange/white wire at dynamic braking solenoid small post. The reading should be 48 to 50 volts (full battery voltage)
with the accelerator pedal either up or fully depressed, key switch OFF and the Forward/Reverse rocker switch in NEU-
TRAL and Tow/Run switch in RUN. If reading is zero volts, check continuity of the orange/white wire to the blue OBC
wire in the six-pin connector located at the OBC. If the continuity of the orange/white wire to the blue OBC wire in the
six-pin connector is present, replace the dynamic braking solenoid.
Test Procedure 9 - Key Switch and Limit Switch Circuit
1. Using a multimeter set to 200 volts DC, place the black lead on battery No. 6 negative post and place the red lead (with
insulation probe) on the green/white wire at the wiper switch six-pin connector (harness side). See WARNING on
page 11-11.
2. With Tow/Run switch in RUN, key switch ON, and Forward/Reverse rocker switch in FORWARD, the voltage
reading should be zero volts. When the accelerator pedal is depressed, the voltage reading should be approx-
• DO NOT TOUCH THE ENERGY DISPLACEMENT MODULE (RESISTOR COIL); IT MAY BE EXTREMELY HOT. A HOT
ENERGY DISPLACEMENT MODULE COULD CAUSE SEVERE BURNS.
WARNING