Troubleshooting Guide - Club Car Gasoline Service Manual

1995-1996 ds golf cars
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TROUBLESHOOTING GUIDE

21A
E
TESTING THE Z-PLUG FOR CONTINUITY AND VOLTAGE INPUT AND OUTPUT
Test procedures begin on page 21-25.
TEST
4
5
22
23
10
11
26
27
16
18
19
20
33
34
43
40
41
DIAGNOSTIC REFERENCE CHARTS
The following flow charts, pages 21-21 through 21-24, can be used as guides to assist in diagnosing specific
failures in the electrical system. There are four separate charts, and each will address different symptoms
that the vehicle might exhibit.
The tests specified in the flow charts are tagged with test numbers that correspond to the numbers of
detailed test procedures following the charts. When the chart specifies that a certain test should be per-
formed, the corresponding test procedure should be performed exactly as instructed.
These detailed test procedures will tell how to test specific components, what the test results should be, and
what further action should be taken. Test procedures begin on page 21-25.
In addition to the comprehensive vehicle wiring diagram on page 21-2, wiring diagrams illustrating specific
circuits can be found along with the general description of each specific circuit on pages 21-5 through 21-19.
WARNING
• THE BATTERY WIRES MUST REMAIN CONNECTED WHILE PERFORMING SOME TEST PRO-
CEDURES. RAISE THE REAR END OF THE VEHICLE AND SUPPORT IT ON JACKSTANDS,
WITH THE REAR WHEELS OFF THE GROUND, WHILE PERFORMING ALL TEST PROCE-
DURES.
Page 21-20
Z-PLUG POSITION
Z1
Red wire voltage input to controller
Z1
Red wire continuity
Z3
Orange/white wire voltage input to controller
Z3
Orange/white wire continuity
Z4
Blue/white wire voltage output from controller
Z4
Blue/white wire continuity
Z5
Brown wire voltage output from controller
Z5
Brown wire continuity
Z6
White wire and Z7 blue wire voltage input to controller
Z6
White wire and Z7 blue wire continuity
Z8
Green/white wire voltage input to controller
Z8
Accelerator limit switch wire continuity (green/white wire and blue wire)
Z9
Yellow wire and Z10 purple wire voltage output from potentiometer
Z9
Yellow wire and Z10 purple wire continuity
Z11
Green wire and Z12 yellow wire continuity
Z13
Red wire and Z14 green wire voltage output from controller
Z13
Red wire and Z14 green wire continuity

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