Club Car 2009-20011 Electric Precedent Maintenance And Service Manual page 123

IQ SYSTEM TROUBLESHOOTING – TPS
TEST PROCEDURE 2 – Onboard Computer Solenoid Lockout Circuit
See General Warnings on page 1-1.
The solenoid lockout circuit disables the vehicle when the battery charger is plugged into the vehicle. Use the following
procedure to test the solenoid lockout circuit:
1. With batteries connected, place the Tow/Run switch in the RUN position.
2. Using a multimeter set to 200 volts DC, place black (–) probe on battery no. 4 (4 x 12-Volt battery set) or battery
no. 6 (6 x 8-Volt battery set) negative post and red (+) probe (with insulation-piercing probe) on the light
blue onboard computer wire (at a point between the OBC and the six-pin connector). The reading should be
approximately 38-42 volts (full battery voltage). If the reading is not 38-42 volts, proceed to step 3. If the reading
is 38-42 volts, proceed to Test Procedure 3 – Solenoid Activating Coil on page 11-15.
3. Place insulation-piercing probe on the light blue 18-gauge wire at a point between OBC six-pin connector and
main wire harness. If reading is 38-42 volts, check the wire terminal connectors inside six-pin connector at
OBC six-pin connector. Make sure pins are properly aligned inside housing. Make sure wire colors match and
are connected to the correct terminals.
4. If reading is zero volts, plug the charger DC cord into the vehicle charger receptacle. If the dash light illuminates
for 10 seconds, the OBC is now powered-up. Unplug the DC cord; the reading at the OBC light blue wire should
be approximately 38-42 volts. If the vehicle now operates normally, the DC cord has powered up the electrical
system. The electrical system should also power-up when the accelerator pedal is pressed. To check the
accelerator pedal function, see Test Procedure 4 – Throttle Position Sensor Voltage on page 11-16.
5. If the dash light illuminates for 10 seconds and the vehicle does not operate:
5.1. Using a multimeter set to 200 volts DC, place black (–) probe on battery number 4 and place red (+) probe
(with insulation-piercing probe) on light blue 18-gauge wire at OBC six-pin connector.
5.2. With Tow/Run switch in the RUN position, the voltage reading should be approximately 48 volts.
6. If the dash light does not illuminate and the vehicle does not operate, check the OBC activation circuit.
6.1. Using a multimeter set to 200 volts DC, place the black (–) probe on the battery no. 4 (4 x 12-Volt
battery set) or battery no. 6 (6 x 8-Volt battery set) negative post and place the red (+) probe (with
insulation-piercing probe) on the red 18-gauge wire located on the OBC side of the six-pin connector.
The reading should be approximately 48 volts. If the reading is incorrect, test the Tow/Run switch and
connecting wires. See Tow/Run Switch on page 11-18.
6.2. Using a multimeter set to 200 volts DC, place the black (–) probe on the battery no. 4 (4 x 12-Volt
battery set) or battery no. 6 (6 x 8-Volt battery set) negative post and place the red (+) probe (with
insulation-piercing probe) on the red 18-gauge 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 correct,
OBC activation circuit has failed. Replace OBC.
TEST PROCEDURE 3 – Solenoid Activating Coil
See General Warnings on page 1-1.
NOTE: Be aware that one of two different solenoids may be found on the vehicle. Visually, the production solenoid is
smaller than the service replacement. On the labels, the larger service replacement solenoid has SOL0605
and the smaller production solenoid has SOL5006. Internally, specifications and test results differ between
the two.
1. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles
on page 1-3.
2. Access the solenoid by removing the electronics module cover. See Electronics Module Cover on page 17-5.
3. Remove the two small wire terminals from the solenoid.
4. Place red (+) probe of the multimeter on the positive (+) solenoid terminal. Place the black (–) probe on the
other small solenoid terminal.
2009-2011 Electric Precedent Maintenance and Service Manual
11
Test Procedures
Page 11-15