Club Car 2009-20011 Electric Precedent Maintenance And Service Manual page 205

EXCEL SYSTEM TROUBLESHOOTING – TPS
on the purple/white wire at a point close to the six-pin connector at the throttle position sensor. The reading should
be approximately 48-50 volts (full battery voltage).
3. If reading is zero volts, check the purple/white wire continuity from the six-pin connector at the sensor to the
16-pin connector at the speed controller. Check terminal positions in six-pin connector at the sensor and the
16-pin connector. If all of the continuity readings are correct and the connectors are wired correctly, replace the
speed controller.
4. With multimeter set to 20 volts DC, place the 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 the red (+) probe (with insulation-piercing probe) on the white wire
at a point close to the six-pin connector at the sensor. The reading should be 5 volts.
5. If reading is zero volts, check the white wire continuity from the six-pin connector at the sensor to the 16-pin
connector at the speed controller. Check terminal positions in six-pin connector at the sensor and the 16-pin
connector. If all of the continuity readings are correct and the connectors are wired correctly, replace the
speed controller.
6. Turn key switch ON and, with multimeter set to 20 volts DC, place the 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 the red (+) probe (with insulation-piercing
probe) on the yellow wire at a point close to six-pin connector at the sensor. The reading should be approximately
0.30 volts with the pedal up. Slowly press the accelerator pedal and note the readings on the multimeter. As the
pedal is pressed, the reading should increase until it reaches 4.15 to 4.45 volts when the pedal is fully pressed.
7. If reading does not increase as the pedal is pressed, replace the accelerator pedal assembly. See Accelerator
Pedal Removal on page 5-6.
8. If the reading is not between 4.15 and 4.45 volts with the pedal fully pressed, the vehicle will not operate at rated
top speed. Replace the accelerator pedal assembly. See Accelerator Pedal Removal on page 5-6.
TEST PROCEDURE 5 – A1 and A2 Motor Voltage
See General Warnings on page 1-1.
1. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands
under the frame rails just forward of each spring mount. See WARNING "Lift only one end..." in General
Warnings on page 1-1. See also following WARNING.
WARNING
• Keep people and equipment clear from rotating rear wheels. Do not allow persons under the car.
Contact with rotating rear wheels could result in serious personal injury.
2. With the batteries connected and using a multimeter set to 200 volts DC, place the black (–) probe on the A2
motor terminal (white wire) and connect the red (+) probe to the A1 (green wire) motor terminal.
3. With Tow/Run switch in the RUN position, place the Forward/Reverse switch in the FORWARD position, turn key
switch to the ON position and slowly press accelerator pedal.
4. As the accelerator pedal is pressed, the voltage reading should increase from approximately 5 volts RMS when
the throttle position sensor limit switch closes, to approximately 48 volts RMS with the accelerator pedal fully
pressed. See following NOTE.
NOTE: Voltage can vary depending on controller speed setting as well as which zone a Guardian equipped vehicle
is located.
Example: Speed setting 1 may only read 30 volts.
4.1. If there is no voltage reading, check the throttle position sensor. See Throttle Position Sensor Voltage
on page 13-16. Also check the continuity of the large posts of the solenoid. See Solenoid Continuity
on page 13-32.
4.2. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric
Vehicles on page 1-3.
2009-2011 Electric Precedent Maintenance and Service Manual
13
Test Procedures
Page 13-17