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ELECTRICAL SYSTEM AND TESTING

Test Procedures

1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 11-15

3. If reading is zero volts, plug the charger DC cord into the vehicle charger receptacle. If the dash light illumi-

nates for 10 seconds, the OBC is now activated and the reading at the OBC blue wire should be approximately
48-50 volts. When the DC cord is disconnected, the solenoids should click on for two seconds and then click
off. If the vehicle now operates normally, the DC cord has powered up the electrical system. The electrical sys-
tem should also power-up when the accelerator pedal is depressed. To check the accelerator pedal function,

see Test Procedure 4.

4. If the dash light illuminates and the solenoids do not click:

4.1.

Using a multimeter set to 200 volts DC, place black lead on battery number 6 and place red lead (with
insulation probe) on blue 18 gauge wire at OBC six-pin connector.

4.2.

With Tow/Run switch in the RUN position, the voltage reading should be approximately 48 volts.

4.3.

If the reading is zero volts, replace the OBC.

5. If the dash light does not illuminate and the solenoids do not click, check the OBC activation circuit.

5.1.

Using a multimeter set to 200 volts DC, place the black lead on battery No. 6 negative post and place the
red lead (with insulation probe) on the red 18 gauge wire (with the yellow fuse holder) located on the
OBC side of the fuse holder. The reading should be approximately 48 volts.

5.2.

If reading is zero volts, test fuse and fuse holder (located in red 18 gauge wire). Using a multimeter set to
200 ¾, connect red (+) lead to one end of fuse and connect black (-) lead to other end of fuse. Multime-
ter should indicate continuity.

5.3.

Place wire probe on the 18 gauge red/white wire (harness side of six-pin connector). Multimeter should
indicate 48 volts. If voltage is correct, check connections in the six-pin connector. If connections are cor-
rect, OBC activation circuit has failed. Replace OBC.

Test Procedure 3 - Voltage At Main Solenoid Activating Coil

1. Place Tow/Run switch in TOW and wait 10 seconds before proceeding.

See WARNING on page 11-11.

Using a

multimeter set to 200 volts DC, place black lead on small post with blue/white wire and place red lead on small post
with blue wire.

2. Place Tow/Run switch in RUN. Solenoid should activate for 2-3 seconds and then deactivate. When solenoid

clicks, voltage reading should be approximately 48 volts (full battery voltage). If the voltage reading is 48 volts
and the solenoid does not click, replace the solenoid.

3. If the voltage reading is zero volts, replace speed controller.

See WARNING on page 11-11.

Test Procedure 4 - Multi-Step Potentiometer (Wiper Switch) Voltage

1. Place Tow/Run switch in RUN. Using a multimeter set to 20 volts DC, place black lead on battery No. 6 negative post

and place red lead (with insulation probe) on purple wire at a point between the six-pin connector and wiper
switch. The reading should be approximately 3.75 volts.

See WARNING on page 11-11.

2. If reading is zero volts, check the purple wire continuity from the connector to the controller, the purple wire

continuity from the connector to the wiper switch, and the six-pin connector at the wiper switch. If all of the
continuity readings are correct, replace the controller.

3. With multimeter set to 200 volts DC, place the red lead on battery No. 1 positive post and the black lead (with

insulation probe) on the white/black wire at a position between the six-pin connector and the wiper switch.
The reading should be approximately 48-50 volts.

4. If reading is zero volts, check white/black wire continuity from six-pin connector to 23-pin connector. Check white/

black wire continuity from six-pin connector to wiper switch. Check terminal positions in six-pin connector at the
wiper switch. If all of the continuity readings are correct, replace the speed controller.

5. With multimeter set to 20 volts DC, place the black lead on battery No. 6 negative post and the red lead (with

insulation probe) on the No. 18 yellow wire at a point between the six-pin connector and the wiper switch.
The reading should be approximately 3.75 volts with the pedal up. Slowly depress the accelerator pedal and
note the readings on the multimeter. As the pedal is depressed, the reading will decrease in increments until
it reaches zero volts when the pedal is fully depressed.