Club Car DS Villager 4, Maintenance And Service Manual

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12
Test Procedures
ELECTRIC VEHICLE - TROUBLESHOOTING
AND ELECTRICAL SYSTEM
4. Pin 6 Green Wire: Access the controller by removing the access panel in the rear body. See following NOTE.
NOTE: The easiest way to test the key switch and MCOR Limit Switch is to check the pin 6 green wire in the 16-pin
connector. Pin 6 is the end of this circuit.
4.1. Locate and connect an insulation-piercing probe to the pin 6 green wire in the 16-pin connector.
4.2. With the key switch in the OFF position and the accelerator pedal at rest, the green wire should show
zero (0) volts.
4.3. With the key switch in the ON position and the accelerator pedal pressed, the green wire should show
BPV which is FOOT INPUT to controller.
– If it shows BPV, then the key switch, MCOR and related wiring is functioning properly.
– If not, first check the key switch and then the MCOR limit switch.
5. Key Switch: Remove instrument panel to access the back of the key switch but do not disconnect wires.
See Key Switch Removal, Section 13, Page 13-1.
5.1. With the key switch in the OFF position:
– The green wire should show BPV coming to the switch.
– The blue wire should show zero (0) volts. If it shows BPV, the switch has failed CLOSED and must
be replaced.
5.2. With the key switch in the ON position:
– The blue wire should show BPV passing through the key switch to the MCOR. If it does not show BPV,
the switch has failed OPEN and must be replaced.
6. MCOR Limit Switch (FOOT INPUT): Remove floormat and cover plate to access the MCOR. See Pedal Group
Removal on page 5-4.
6.1. With the key switch in the ON position:
– With an insulation-piercing probe, check voltage of the blue wire in the MCOR 2-pin connector. It should
show BPV coming to the MCOR. If not, check wiring.
– With an insulation-piercing probe, check voltage of the green wire in the MCOR 2-pin connector. It should
show zero (0) volts with the accelerator pedal at rest. Press the accelerator pedal and the green wire
should show BPV passing through the MCOR to the controller for FOOT INPUT. If not, replace MCOR.
See MCOR Removal on page 13-8.
TEST PROCEDURE 6 – Forward/Reverse Rocker Switch
See General Warnings on page 1-2.
NOTE: This is a voltage test.
The Forward/Reverse Switch provides FORWARD INPUT and REVERSE INPUT to the controller.
If the controller sees both FORWARD INPUT and REVERSE INPUT at the same time, the reverse buzzer will
sound in all FNR positions and the vehicle will not operate in either direction. Common causes of this include
corrosion across the contacts inside the switch, water inside the switch, or a switch that has failed CLOSED.
Forward/Reverse Rocker Switch Test with the CDT Handset
1. Turn the key switch to the OFF position and place the Forward/Reverse switch in the NEUTRAL position.
2. Connect the CDT to the vehicle.
3. Test FORWARD INPUT.
3.1. Access the Monitor menu and select FORWARD INPUT by using the SCROLL DISPLAY buttons. The CDT
should indicate OFF when the Forward/Reverse switch is in the NEUTRAL or REVERSE position.
Page 12-18 2020 Precedent,Villager 2 and 4 Maintenance and Service Manual