Club Car 1998 Maintenance And Service Manual Supplement page 32

11
ELECTRICAL SYSTEM AND TESTING
to the three-pin connector. If the wire continuity is correct, replace the controller.
3.3. If the reading is below 3.50 volts, replace the controller.
3.4. If the voltage reading is correct, proceed to step No. 4.
4. Check voltage at light green wire:
4.1. Using a multimeter set on 20 volts DC, place the black lead on battery No. 6 negative post and place the
red lead on the light green wire female terminal in the three-pin connector. The voltage reading should
be from 4.60 to 4.90 volts.
4.2. If the voltage is zero volts, check the continuity of the light green wire from the 23-pin connector to the
three-pin connector. If the continuity is correct, replace the controller.
4.3. If reading is below 3.50 volts, check wire/plug continuity and replace the controller if necessary.
5. Reconnect the three-pin connector at the motor speed sensor. Using a multimeter set to 20 volts DC, place
the black lead on battery No. 6 negative post and place the red lead (with insulation probe) on the green wire
between the three-pin connector and the motor speed sensor.
5.1. Raise one rear wheel off ground. Slowly turn the rear wheel to rotate the motor armature. As the arma-
ture rotates, the voltage reading should alternate from zero to approximately 4.85 volts. The voltage
reading will fluctuate from zero to 4.85 volts and back to zero four times for each revolution of the
motor armature
5.2. If there is no voltage reading, or the voltage reading is not above 3.50, replace the motor speed sensor.
6. If vehicle does not operate and the main solenoid does not click, but the dynamic braking solenoid does click
when the key switch is turned ON or OFF, the motor speed sensor may be shorted. To test for this condition,
disconnect the motor speed sensor and attempt to drive the vehicle. If the vehicle operates normally, replace
the motor speed sensor. If the dynamic braking solenoid continues to click each time the key switch is turned
ON or OFF with the motor speed sensor disconnected, replace the controller.
NOTE
• THE VOLTAGE READING OF 4.85 IS AN APPROXIMATE READING. THE ACTUAL READING MAY VARY FROM 4.50 TO
4.90 VOLTS.
Test Procedure 15 - Main Solenoid Continuity
1. Raise rear wheel off ground. Using a multimeter set to 200k ohms, place the black lead on the main solenoid
large post with the yellow 6 gauge wire and place the red lead on the large post with the red 6 gauge wire.
The reading should be no continuity. See DANGER and WARNING on page 11-11.
2. With Tow/Run switch in RUN, turn the key switch to ON, place the Forward/Reverse rocker switch in FOR-
WARD and depress the accelerator pedal. The solenoid should click and the meter should show continuity. If
the reading is no continuity, replace the solenoid.
Test Procedure 16 - Forward/Reverse Rocker Switch
1. Disconnect the three wires from the rocker switch. Using a multimeter set to ohms, place the black lead on
the white wire terminal 3 position on the rocker switch, and place the red lead at the red/white wire terminal
2 position. With the switch in NEUTRAL or REVERSE, there should be no continuity. With the switch in FOR-
WARD, there should be continuity. If the readings are incorrect, replace the switch. See WARNING on page
11-11.
2. Place the black lead on the blue wire terminal 1 position on the rocker switch and place the red lead on the
red/white wire terminal. With the switch in REVERSE, there should be continuity. If the readings are incorrect,
replace the switch.
Page 11-20 1998/1999 PowerDrive Plus Maintenance and Service Supplement
Test Procedures