Club Car Precedent Villager 2, Maintenance And Service Manual

Page: 153 / 414

ELECTRIC VEHICLE - EXCEL SYSTEM
TROUBLESHOOTING Test Procedures
12
the multimeter should show a change in resistance. If not, replace the solenoid. See Solenoid Removal on
page 13-12.
TEST PROCEDURE 10 – Charger Interlock
See General Warnings on page 1-2.
Controller Interlock Function Test with the CDT Handset
1. If necessary, see Testing Basics on page 12-11.
2. Connect the CDT to the vehicle.
3. Access the Monitor menu and select CHARGER INHIBIT by using the SCROLL DISPLAY buttons. The CDT
should indicate OFF.
4. Insert the charger DC cord into the vehicle's charger receptacle.
5. In a few seconds, the CDT should indicate ON and the vehicle can no longer be driven. If not, check the KEY,
FORWARD, REVERSE and FOOT INPUTS to the controller.
– If the CDT does not indicate ON, check circuit wiring and DC plug connection. See the following procedure
Testing the Interlock Circuit .
– If the CDT does indicate ON, but the vehicle can still be driven, replace the controller. See Speed Controller
Removal, Section 13, Page 13-11.
Testing the Interlock Circuit
The charger interlock circuit consists of a 48V power source through the RUN/TOW switch, three sonic welds, a
15-amp fuse, a 10k Ohm resistor, a bullet connector, the charger receptacle blue wire and DC plug.
See following
NOTE. Use the following procedure to test the charger interlock circuit:
NOTE: The following steps involve testing voltage and resistance.
At the charger end of the DC cord, the black wire and blue wire are crimped together in the same fork terminal.
This closes the circuit once the DC cord plug is inserted into the charger receptacle.
1. With batteries connected, place the Tow/Run switch in the RUN position.
2. Remove electronics module cover. See Electronics Module Cover Removal, Section 13, Page 13-5.
3. Check 15-amp fuse: See Test Procedure 4 – 15-Amp Fuse on page 12-15.
4. Check power: Using a multimeter set to 200 volts DC, place red (+) probe (with insulation-piercing probe) on the
light blue wire (pin 5 of the 16-pin connector) and black (–) probe on B- terminal of controller. The reading should
be approximately 42 to 46 volts. If the reading is not approximately 42 to 46 volts, proceed to check the 10k Ohm
resistor. If the reading is approximately 42 to 46 volts, check continuity of circuit wires.
5. Check 10k Ohm resistor: Set multimeter to 20k Ohms. Remove the 15-amp fuse. With the red (+) probe (with
insulation-piercing probe) still on the light blue wire (pin 5 of the 16-pin connector), place the black (–) probe to the
red wire terminal in the 15-amp fuse holder. The reading should be approximately 10.0k Ohms. If the reading is
not approximately 10.0k Ohms, replace the resistor or main wire harness
(Figure 12-2, Page 12-4) .
6. Check continuity: Set multimeter to Continuity test. With the red (+) probe (with insulation-piercing probe) still
on the light blue wire (pin 5 of the 16-pin connector), place the black (–) probe in the blue wire terminal of the
charger receptacle. The meter should beep to indicate continuity. If not, check bullet connector of blue wires.
Next, probe from the pink wire terminal in the 15-amp fuse holder to the large solenoid post with the red wires
attached. The meter should beep to indicate continuity. If not, verify Tow/Run switch is in RUN and check the
red-to-pink wire spade connector near the solenoid.
If the meter does not indicate continuity, check and repair related connections, Tow/Run switch and wiring. If
necessary, replace affected wire harness, charger receptacle or Tow/Run switch.
2019 Precedent Villager 2 Maintenance and Service Manual Page 12-21