Club Car DS Villager 4, Maintenance And Service Manual

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12
Test Procedures
ELECTRIC VEHICLE - TROUBLESHOOTING
AND ELECTRICAL SYSTEM
TEST PROCEDURES
Using the following procedures, the entire electrical system can be tested without major disassembly of the vehicle.
WARNING
• If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured.
Failure to properly route and secure wiring could result in vehicle malfunction, property damage,
personal injury, or death.
For many tests, the electronics module cover must be removed to gain access to the various components that are
mounted on the component mounting plate.
See Electronics Module Cover on page 13-6. See following WARNING.
WARNING
• Shorting of battery terminals can cause personal injury or death.
– Do not place component mounting plate directly on top of batteries when removing or installing
plate.
– Remove plate from vehicle completely.
After test procedures are completed, be sure to replace the cover. See Electronics Module Cover on page 13-6.
See following CAUTION.
CAUTION
• Exposure to water may damage electronic components.
– Do not operate vehicle without the cover properly installed.
– Do not direct a water stream in area of the cover.
TESTING BASICS
• To use the CDT, the Tow/Run switch must be in the RUN position. The Tow/Run switch provides power to the logic
board and power board inside the controller.
• Battery Pack Voltage (BPV) will be referenced throughout the test procedures. BPV is accessed in Test Procedure
1 – Batteries / Voltage Check (BPV) on page 12-13 .
• The Tow/Run switch powers the key switch, controller, Forward/Reverse switch, 15-amp fuse, and reverse buzzer.
• The key switch powers the MCOR 2-pin circuit, Forward/Reverse switch, solenoid, and the female bullet connector
(W34 shown on .
• The MCOR 3-pin circuit, motor speed sensor circuit, the communication point for the car device (white/black wire
in position 13 of the 16 pin connector), and charge indicator light is powered by the controller (with Tow/Run
switch in RUN).
• The 2-amp fuse is powered directly by the batteries via the solenoid and carries BPV to the connected car
device. No switch is involved.
• The term “back-probe” refers to probing the side of a connector that the wire enters. This is usually done when the
connector must remain connected to a device. See following CAUTION.
Page 12-12 2020 Precedent,Villager 2 and 4 Maintenance and Service Manual