Club Car Gasoline Service Manual page 418

Numerical Listing of Test Procedures, Continued:
21A
42. Motor Sensor 3-Wire Plug Connection
43. Z11 (Green Wire) and Z12 (Yellow Wire) Continuity
E
TEST PROCEDURES
Test Procedure 1 - Battery Pack Voltage
1. Turn the key switch to OFF and place the forward and reverse switch in NEUTRAL. Leave the batteries
connected and leave the Z plug connected to the controller.
2. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Place
jackstands under the axle tubes to support the vehicle. The rear wheels must be off the ground.
WARNING
• LIFT ONLY ONE END OF A VEHICLE AT A TIME. BEFORE LIFTING, LOCK THE BRAKES AND
CHOCK THE WHEELS THAT REMAIN ON THE FLOOR. USE A SUITABLE LIFTING DEVICE
(CHAIN HOIST OR HYDRAULIC FLOOR JACK) WITH 1000 LBS. (454 KG.) MINIMUM LIFTING
CAPACITY. DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION. ALWAYS
USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE.
3. Set a multimeter to Volts DC, then place the black (-) probe on the negative (-) post of battery No. 6 and
the red (+) probe on the positive (+) post of battery No. 1 (Figure 21-21).
4. Record the reading for reference (this reading will be useful when performing other test procedures
also). This reading will be referred to as Full Battery Voltage.
Battery Pack Voltage (Under Load)
1. Place alligator clips (Radio Shack Catalog No. 270-354A or equivalent) on the multimeter test leads:
Connect the red (+) alligator clip to the positive post of battery No. 1 and the black (-) alligator clip to the
negative post of battery No. 6.
2. Put seat bottom in place and set the multimeter on the seat.
3. With the multimeter set on DC Volts (DCV), drive the vehicle and note the voltage reading.
• A fully charged set of batteries in good condition should read between 46-48 volts while under load.
• A reading of 36-46 volts indicates discharged or defective batteries.
• A reading of 32 volts or lower will not activate the solenoid and the car will not move.
Page 21-26
DATA HOLD
AC/DC 500V MAX
250V MAX
AC V
DC V
OFF
FRONT OF CAR
BATTERY
BANK
+
+
-
+
-
5
6
FIGURE 21-21
+
-
+
-
2
1
+
-
-
3
4