Club Car 1998 Maintenance And Service Manual Supplement page 30

11
ELECTRICAL SYSTEM AND TESTING
imately 48 volts (full battery voltage). If the voltage reading is zero with the accelerator pedal depressed,
check the key switch and limit switch circuit using the following test procedures.
2.1. Using a multimeter set to 200 volts DC, place black lead on battery No. 6 negative post and place red
lead (with insulation probe) on blue wire between six-pin connector and wiper switch, the reading
should be approximately 48 volts (full battery voltage).
2.2. If the reading is zero volts, check the key switch continuity and the continuity of the blue wire that goes
from the key switch to the six-pin connector at the wiper switch.
2.3. If the reading is approximately 48 volts, proceed to step 3.
3. Using a multimeter set to 200 volts DC, place the black lead on battery No. 6 negative post and place the red
lead (with insulation probe) on the blue wire at the wiper switch six-pin connector (harness side). With the key
switch ON and the Tow/Run switch in the RUN position, the reading should be approximately 48 volts (full
battery voltage).
3.1. If the reading is zero volts, check the position of the terminal pins and sockets in the six-pin connector
and make sure wire colors match. Check the blue wire on each side of the six-pin connector (at the
wiper switch) and make sure it is securely crimped to the terminal.
3.2. If the reading is approximately 48 volts, proceed to step 4.
4. Using a multimeter set to 200 volts DC, place the black lead on battery No. 6 negative post and place the red
lead (with insulation probe) on the green/white wire at a point between the wiper switch and the six-pin con-
nector. With the Tow/Run switch in the RUN position, the key switch ON, the Forward/Reverse rocker switch in
NEUTRAL and the accelerator pedal depressed, the reading should be approximately 48 volts (full battery
voltage).
4.1. If the reading is zero volts, test the continuity of the accelerator limit switch and the green/white wire.
4.2. If the reading is approximately 48 volts, proceed to step 5.
5. Place black lead of multimeter (set to 200 volts DC) on negative post of battery No. 6 and red lead (with insulation
probe) on the green/white wire at a point between the six-pin connector and the wire harness conduit. With the key
switch ON and the accelerator pedal depressed, the reading should be approximately 48 volts.
5.1. If reading is zero volts, make sure the terminals are properly seated in the plug housing and the green/
white wire is securely crimped to the terminal in the six-pin connector at the wiper switch.
5.2. If the reading is approximately 48 volts, check the green/white wire at the pin 3 position in the 23-pin
connector to make sure the terminal socket is properly seated in the plug and the wire is securely
crimped to the terminal. See Test Procedure 10.
Test Procedure 10 - 23-Pin Connector
1. With Tow/Run switch in the TOW position, disconnect 23-pin connector from controller. Insert small sized
screwdriver under plug clip and turn to release clip from connector. 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, then disconnect the red cap in plug housing before terminal sockets are repositioned.
After the terminal has been pushed into the housing, gently pull on the wire to ensure it is locked into place.
Once the terminal socket is in position, press the red cap down until it snaps into place. See WARNING on
page 11-11.
2. Check wires in the plug to make sure none are broken at the terminal pin crimp. Repair or replace as required.
3. When connecting the 23-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.
Test Procedure 11 - Onboard Computer Silicon Controlled Rectifier (SCR) Circuit
1. A silicon controlled rectifier (SCR) acts as a switch between the two black wires in the OBC to complete the negative
Page 11-18 1998/1999 PowerDrive Plus Maintenance and Service Supplement
Test Procedures