22
Test Procedures
ELECTRICAL SYSTEM AND TESTING:
ELECTRIC VEHICLES
connector. Make sure pins are properly aligned inside housing. Make sure wire colors match and are connected
to the correct terminals.
4.
Place insulation-piercing probe on the light blue 18-gauge wire (2) at a point between speed controller 24-pin
connector and main wire harness
. If reading is not 40-43 volts, check the wire terminal
connectors inside the 24-pin connector or for possible broken wires. Make sure pins are properly aligned inside
housing. Make sure wire colors match and are connected to the correct terminals.
5.
If reading is zero volts, plug the charger DC cord into the vehicle charger receptacle. If the dash light illuminates
for 10 seconds, the OBC is now powered-up. Unplug the DC cord; the reading at the OBC blue wire should be
approximately 40-43 volts. If the vehicle now operates normally, the DC cord has powered up the electrical
system. The electrical system should also power-up when the accelerator pedal is pressed. To check the
accelerator pedal function,
see Test Procedure 4 – MCOR Voltage on page 22-13
.
6.
If the dash light illuminates for 3 seconds and the vehicle does not operate, proceed to Test Procedure 4 –
MCOR Voltage on page 22-13.
7.
If the dash light does not illuminate and the vehicle does not operate, check the OBC activation circuit.
7.1. Set a multimeter to 200 volts DC. Place the black (–) probe on the battery no. 8 negative post and place
the red (+) probe (with insulation-piercing probe) on the red 18-gauge wire located on the OBC side of
the six-pin connector. The reading should be approximately 48 volts. If the reading is incorrect, test the
continuity from the pink wire on the solenoid to the red pin on the OBC harness.
7.2. Set a multimeter to 200 volts DC. Place the black (–) probe on the battery no. 8 negative post and place the
red (+) probe (with insulation-piercing probe) on the blue 18-gauge wire (harness side of six-pin connector).
Multimeter should indicate 40-43 volts. If voltage is not correct, check connections in the six-pin connector.
If connections are correct, OBC activation circuit has failed. Replace OBC.
1
2
Figure 22-4
Test Blue OBC Wire (+)
Figure 22-5
Test Light Blue 18-Gauge Wire at 24-pin
Connector (+)
TEST PROCEDURE 3 – Solenoid Activating Coil
See General Warning on page 1-1.
1.
Disconnect the batteries and discharge the controller.
See Disconnecting the Batteries – Electric Vehicles,
2.
Remove the two small wire terminals from the solenoid.
3.
Place red (+) probe of the multimeter on the positive (+) solenoid terminal. Place the black (–) probe on the
other small solenoid terminal. A reading of 180 to 190 ohms should be obtained
. If
not, replace the solenoid.
4.
If a failed diode was removed, replacement of the diode is not necessary because a diode that serves the
same function is located within the speed controller.
Page 22-12
2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual
