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ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE
Troubleshooting
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
Page 21-15
21
TEST PROCEDURE 6 – TOW/RUN SWITCH
See General Warning on page 1-1.
Tow/Run Switch Test with the Diagnostic Handset
1. With the Tow/Run switch in the RUN position, connect the handset to the vehicle.
See Plugging the
Handset into the Vehicle on page 22-1.
2. Immediately after the handset is connected to the vehicle, the screen should display a copyright notice
and the Diagnostic Handset model number.
3. If the handset display screen is blank, drive the vehicle a short distance to activate the onboard computer.
4. If the vehicle will not operate, proceed to Tow/Run Switch Test without the Diagnostic Handset.
5. If the handset display screen begins to work after the vehicle has been driven, turn the key switch to the
OFF position and proceed to step 6; otherwise, perform the following procedure, Tow/Run Switch Test
without the Diagnostic Handset.
6. With the handset still connected to the vehicle, place the Tow/Run Switch in the TOW position and wait
90 seconds.
7. If the handset display screen goes blank after 90 seconds, the Tow/Run switch and connecting wires are
operating correctly.
8. If the handset display screen is still active after 90 seconds, the switch has failed closed. Replace the
Tow/Run switch.
See Tow/Run Switch Removal on page 23-7.
Tow/Run Switch Test without the Diagnostic Handset
1. Set a multimeter to 200 volts DC and with the batteries connected, connect the black (–) probe to the neg-
ative post of battery no. 4 and connect red (+) probe (with insulation-piercing probe) on the light green
wire close to the two-pin connector on the Tow/Run switch.
2. With the Tow/Run switch in the RUN position, the reading should be approximately 48-50 volts. With the
switch in the TOW position, the reading should be below approximately 5 volts.
3. If the reading is above 5 volts with the switch in the TOW position, replace the switch.
4. If the reading is below 5 volts with switch in the RUN position, check continuity of the two-pin connector
and the pink 18-gauge wire from the large post of the solenoid to the two-pin connector at the Tow/Run
switch.
5. If the two-pin connector and pink wire continuity readings are correct, replace the Tow/Run switch.
TEST PROCEDURE 7 – BATTERY PACK VOLTAGE (UNDER LOAD)
See General Warning on page 1-1.
1. Before proceeding with this test procedure, the batteries must be connected and fully charged. Connect
the positive (+) lead of a 36 to 48-volt battery discharge machine (CCI P/N 101831901), to battery no. 1
positive post and connect the negative (–) lead to battery no. 4 negative post. Record the voltage reading
from discharge machine.
2. Turn the discharge machine on and record the voltage reading of battery pack while under load.
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 failed 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. If the voltage of the batteries is below
32 volts, the batteries are deeply discharged or have failed.
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