Club Car 2009-20011 Electric Precedent Maintenance And Service Manual page 248

14
Test Procedures
WARNING
• The Forward/Reverse switch must be in the neutral position to avoid personal injury due to contact
with rotating wheels.
5.2. With Tow/Run switch in the RUN position, key switch in the ON position, and Forward/Reverse rocker switch
in the NEUTRAL position, the voltage reading should be zero volts. When the accelerator pedal is pressed,
the voltage reading should be approximately 48 volts (full battery voltage).
5.3. If the voltage reading is 48 volts when the accelerator pedal is not pressed, replace the MCOR. See
MCOR Removal on page 17-8.
5.4. If the voltage reading is zero volts when the accelerator pedal is pressed, check the limit switch circuit using
the following test procedures.
5.4.1. 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 the place red (+) probe (with
insulation-piercing probe) on the blue wire where it connects to the MCOR. With the key switch ON,
the reading should be approximately 48 volts (full battery voltage).
5.4.2. If the reading is zero volts, check the continuity of the blue wire that goes from the key switch to
the MCOR.
5.4.3. If the reading is approximately 48 volts, proceed to the following step.
5.4.4. 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 green wire where it connects to the MCOR. With the Tow/Run
switch in the RUN position, the key switch ON, the Forward/Reverse rocker switch in NEUTRAL and
the accelerator pedal pressed, the reading should be approximately 48 volts (full battery voltage).
5.4.5. If the reading is zero volts, test the continuity of the MCOR limit switch and the green wire. If the limit
switch does not pass the continuity test, replace the MCOR. See MCOR Removal on page 17-8.
TEST PROCEDURE 9 – 16-Pin Connector
See General Warnings on page 1-1.
1. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles
on page 1-3.
2. Disconnect the 16-pin connector from the speed controller. Inspect terminal ends inside plug to ensure they are in
position and seated in plug housing. If any terminals look like they are not pushed all the way into the connector,
gently push the terminals until they are firmly seated in the 16-pin connector. After each terminal has been
pushed into the housing, gently pull on the wire to ensure it is locked into place.
3. Check wires in the plug to make sure none are broken at the terminal pin crimp. Repair or replace as required.
4. Check the wire colors of each wire and make sure that the colors for each pin position match the wire colors in the
wiring diagram. See Wiring Diagrams on page 14-3.
5. When connecting the 16-pin connector to the controller, push plug into controller receptacle with enough force to
lock plug into place. An audible click will be heard when plug is properly seated to the controller.
A procedure is provided for testing each of the wires in the 16-pin connector. Refer to the following chart for the
appropriate procedure for each pin in the 16-pin connector.
If the results of any of the referenced procedures are different from those described in the procedure, check the
continuity of the wires in the wire harness and test the connected components with the appropriate test procedures.
See Index of Test Procedures.
TABLE CONTINUED ON NEXT PAGE
Page 14-22 2009-2011 Electric Precedent Maintenance and Service Manual
EXCEL SYSTEM TROUBLESHOOTING – MCOR