Club Car 1998 Maintenance And Service Manual Supplement page 31

ELECTRICAL SYSTEM AND TESTING
side of the circuit to allow the charger to charge the batteries. See WARNING on page 11-11.
2. A black 10 gauge wire is connected to the battery negative (B-) terminal on the controller and goes to the
onboard computer. Another black 10 gauge wire is attached to the onboard computer and goes to the
charger receptacle.
3. Use the following procedure to test the SCR:
3.1. Using a multimeter set to 200 volts DC, place the red lead on the positive post of battery No. 1 and place
the black lead on the receptacle fuse terminal that has the black 10 gauge OBC wire attached to it. The
reading should be approximately 36-42 volts.
3.2. If the reading is zero volts, check the black 10 gauge wire connections at the controller and receptacle.
Check the continuity of the black 10 gauge wires. If the wires and connections are okay, the SCR has
failed. Replace the OBC. If the reading is correct, proceed to step 4.
4. Plug in AC and DC cords. When charger relay clicks ON, reading should be approximately 48 volts (full battery voltage).
If the reading does not rise from approximately 40 volts to full battery voltage when the DC cord is plugged in and the
relay clicks ON, check the receptacle fuse and black wire terminal socket in the receptacle.
Test Procedure 12 - OBC Gray Wire and Fuse
1. Using a multimeter set to 200 volts DC, connect red lead to positive post of battery No. 1 and black lead (with
insulation probe) to gray 16 gauge wire at a point between fuse and receptacle. Reading should be approxi-
mately 48 volts. If reading is zero volts, check gray wire fuse and fuse holder. See WARNING on page 11-11.
2. If the reading in step 1 is 48 volts, plug the DC cord into the vehicle's charger receptacle. The voltage reading
should drop to approximately 4.0 volts before the charger relay clicks on.
3. When the charger relay is activated, the reading should rise to approximately 48 volts.
4. If voltage does not drop to approximately 4.0 volts when the DC cord is plugged in and then rise to approximately 48
volts when the charger relay clicks ON, the gray wire circuit in the OBC has failed. Replace the OBC.
Test Procedure 13 - Voltage At Charger Receptacle Red Wire Socket
1. Using a multimeter set to 200 volts DC, place the black lead on the negative post of battery No. 6 and place the red
lead on the charger receptacle socket connected to the red 10 gauge wire. The reading should be 48-50 volts (full bat-
tery voltage). See WARNING on page 11-11.
2. If the reading is zero volts, check the continuity of the 10 gauge red wire from the positive post of battery No. 1 to the
receptacle socket.
Test Procedure 14 - Motor Speed Sensor
1. Disconnect the three-pin connector at the motor speed sensor. See WARNING on page 11-11.
2. Check voltage at black wire:
2.1. Using a multimeter set to 200 volts DC, place the red lead on battery No. 1 positive post and place the black lead
on the black wire terminal socket in the three-pin connector. The voltage reading should be 48 to 50 volts (full
battery voltage).
2.2. If the reading is zero volts, check the continuity of the black wire from the 23-pin connector to the three-
pin connector. If the continuity is correct, replace the controller.
3. Check voltage at red/green wire:
3.1. With Tow/Run switch in RUN and using a multimeter (set on 20 volts DC), place black lead on battery No.
6 negative post and place red lead on red/green wire terminal socket in three-pin connector. Voltage
reading should be from 5.01 to 5.08 volts.
3.2. If the voltage reading is zero volts, check the continuity of the red/green wire from the 23-pin connector
1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 11-19
11
Test Procedures