ELECTRICAL SYSTEM AND TESTING: ELECTRIC
VEHICLES
Test Procedures
22
4.6. If the key switch operates as described in the previous steps, install the dash panel in the reverse order of
removal and proceed to test the MCOR limit switch.
4.7. Connect the batteries.
See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4.
5.
Test the MCOR limit switch.
See following NOTE.
NOTE:
Make sure that the key switch is operating correctly and that the key switch and dash panel are properly
installed before proceeding.
5.1. With batteries connected and using a multimeter set 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 green
wire close to the two-pin connector on the MCOR.
5.2. With Tow/Run switch in the RUN position, key switch in the ON position, and Forward/Reverse rocker switch
in the NEUTRAL position, the voltage reading should be zero volts. When the accelerator pedal is pressed,
the voltage reading should be approximately 48 volts (full battery voltage).
5.3. If the voltage reading is 48 volts when the accelerator pedal is not pressed, check the pedal group for
proper adjustment.
See Accelerator and Brake Pedal Group Section.
5.4. If the voltage reading is zero volts when the accelerator pedal is pressed, check the key switch circuit using
the following test procedures.
5.4.1. Set a multimeter to 200 volts DC. Place black (–) probe on battery no. 8 negative post and the place
red (+) probe (with insulation-piercing probe) on the blue wire where it connects to the MCOR. With
the key switch ON, the reading should be approximately 48 volts (full battery voltage).
5.4.2. If the reading is zero volts, check the continuity of the blue wire that goes from the key switch to
the MCOR.
5.4.3. If the reading is approximately 48 volts, proceed to the following step.
5.4.4. 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 green wire where it connects to the
MCOR. With the Tow/Run switch in the RUN position, the key switch ON, the Forward/Reverse
rocker switch in NEUTRAL and the accelerator pedal pressed, the reading should be approximately
48 volts (full battery voltage).
5.4.5. If the reading is zero volts, test the continuity of the MCOR limit switch. If the limit switch does not
pass the continuity test, replace the MCOR.
See MCOR Removal on page 24-6.
TEST PROCEDURE 10 – 24-Pin Connector
See General Warning on page 1-1.
1.
Disconnect the batteries and discharge the controller.
See Disconnecting the Batteries – Electric Vehicles,
2.
Disconnect the 24-pin connector from the speed controller. Inspect terminal ends inside plug to ensure they are in
position and seated in plug housing. If any terminals look like they are not pushed all the way into the connector,
gently push the terminals until they are firmly seated in the 24-pin connector. After each terminal has been
pushed into the housing, gently pull on the wire to ensure it is locked into place.
3.
Check wires in the plug to make sure none are broken at the terminal pin crimp. Repair or replace as required.
4.
Check the wire colors of each wire and make sure that the colors for each pin position match the wire colors in
the wiring diagram.
See Wiring Diagrams beginning on page 22-2
5.
When connecting the 24-pin connector to the controller, push plug into controller receptacle with enough force to
lock plug into place. An audible click will be heard when plug is properly seated to the controller.
A procedure is provided for testing each of the wires in the 24-pin connector. Refer to the following chart for the
appropriate procedure for each pin in the 24-pin connector.
2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual
Page 22-19
