Club Car Gasoline Service Manual page 436

Test Procedure 31 - Battery Warning Light Circuit, Continued:
21A
4. Disconnect the battery wires, negative wire first (Figure 21-2, Page 21-3).
5. Remove the center dash (See Removing the Battery Warning Light, Page 20-41).
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6. Disconnect the 18-gauge brown wire from battery warning light.
7. Set the multimeter to ohms (Ω), connect the black (-) probe to the male side of the brown wire spade
connector. Connect the red (+) probe to the brown wire female spade that was disconnected from the
battery warning light. Reading should be continuity. If reading is incorrect, repair or replace the wire.
8. Disconnect the 18-gauge orange/white wire from battery warning light.
9. Set the multimeter to ohms (Ω), connect the black (-) probe to the female spade connector on the
orange/white wire and connect the red (+) probe to the key switch terminal with the orange/white wire.
The reading should be continuity. If the reading is incorrect, repair or replace the wire.
10. If both wires test good, then replace the battery warning light.
Test Procedure 32 - Potentiometer Voltage Output Test
1. Turn the key switch to OFF and place the forward and reverse switch in NEUTRAL. Disconnect the bat-
teries. Leave the Z plug connected to the controller.
2. Disconnect the 3-wire plug at the potentiometer and disconnect the green/white wire at the spade con-
nector near the 3-wire plug (Figure 21-64, Page 21-42).
3. Connect the Calibration Test Module (CTM) (Club Car Part No. 1018871-01) to the 3-wire plug from the
potentiometer, and connect the green wire from the Calibration Test Module to the green/white wire
from the accelerator switch.
4. With the accelerator pedal in the up position (not depressed), the reading should be more than 3 volts.
With the accelerator fully depressed, the reading should be zero volts. If either reading is incorrect,
adjust (See Section 6, Page 6-19) or replace the potentiometer (See Section 20, Page 20-37).
5. Turn the key switch ON and slowly depress the accelerator pedal until the accelerator limit switch clicks
on and the red light in the CTM illuminates. The reading should be 3.40 ±.02 volts when the red light
first illuminates. If the reading is below 3.0 volts when the red light comes on, a high pedal detect func-
tion in the controller prevents the main solenoid from activating. If the reading is not 3.40 ±.02 volts
when the red light comes on, adjust or replace the potentiometer.
6. If all readings are zero, check the 3-wire plug connection. If the connection is good, replace the poten-
tiometer.
Test Procedure 33 - Voltage at the Z9 (Yellow Wire) and Z10 (Purple Wire) Positions
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. Disconnect the 3-wire connector from the potentiometer.
3. Place the black (-) probe of a multimeter, set to Volts DC, on the negative (-) post of battery No. 6 and
place the red (+) probe in the yellow wire female terminal in the 3-wire plug (Figure 21-65). The reading
should be 4.5 to 5.0 volts. If the reading is incorrect, check continuity of the yellow wire from the Z plug
to the 3-wire plug.
4. Place the black (-) probe of a multimeter, set to Volts DC, on the negative (-) post of battery No. 6 and
place the red (+) probe in the purple wire female terminal in the 3-wire plug (Figure 21-66). The read-
ing should be 4.5 to 5.0 volts. If the reading is incorrect, check continuity of the purple wire from the Z
plug to the 3-wire plug.
5. Place the black (-) probe of a multimeter, set to Volts DC, in the white/black wire female terminal in the
3-wire plug and place the red (+) probe on the positive (+) post of battery No. 1 (Figure 21-67). The
reading should be Full Battery Voltage. If the reading is incorrect, check the bullet connector located in
the white/black wire approximately six inches from the controller. If the bullet connector is plugged in,
repair or replace the white/black wire.
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