section 11–electrical system and testing
Contents
1. ARE UNDER DECAL TARGET POINTS TEST BUTTON Figure 11 23 Test Multi step Potentiometer Figure 11 24 Calibration Test Module 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 11 17 ELECTRICAL SYSTEM AND TESTING Circuit Testing THREE PIN CONNECTOR TO POTENTIOMETER WIRE HARNESS TO THE F amp R SWITCH Figure 11 25 Three Pin Connector Test Procedure 10 Solid State Speed Controller Read DANGER and WARNING on page 11 1 DANGER QT 4 e TURN KEY TO OFF PLACE FORWARD REVERSE HANDLE IN NEUTRAL AND DISCONNECT BATTERY CABLES AS SHOWN IN FIGURE 11 1 PAGE 11 2 FAILURE TO DO SO MAY CAUSE THE VEHICLE TO RUN OVER YOU RESULTING IN SEVERE INJURY OR DEATH SN CONTROLLER CONTROLLER 9 vo N 8222 200 SETTING 200 SETTING Figure 11 26 Test Input Voltage Figure 11 27 Test Output Voltage 1 Because the solid siate soeed controller is a sealed solid state unit it requires almost no maintenance It is recommended however the following two operations be done occasionally 1 1 Make sure electrical connections to controller are tight When checking controller bus bar connections for tightness be sure to use double wrench technique to avoid stressing bus bars and cracking seals 1 2 Remove any corrosion or accumulation of dirt acid fertilizer etc from the terminal area It is especially i2. 11 5 ELECTRICAL SYSTEM AND TESTING Electrical Circuits BATTERY CONDITION INDICATOR CONTINUOUSLY VARIABLE POTENTIOMETER ON BOARD COMPUTER Vay S THREE PIN ae PLUG oh e a MOTI3A day FORWARD REVERSE SWITCH RE AR S or a Figure 11 5 Wiring Diagram Carryall VI Trans Porter Trans Sender Page 11 6 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement ELECTRICAL SYSTEM AND TESTING Electrical Circuits KEY BATTERY SWITCH CONDITION INDICATOR CONTINUOUSLY VARIABLE POTENTIOMETER ONBOARD COMPUTER 2 S 7 E THREE PIN MOTI3A FUSE AND RECEPTACLE Figure 11 6 Wiring Diagram Resort Villager 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 11 7 ELECTRICAL SYSTEM AND TESTING Troubleshooting Guide TROUBLESHOOTING GUIDE DIAGNOSTIC REFERENCE CHARTS Use these charts as a starting point for system troubleshooting More detailed system testing instruc tions follow Battery Warning Light In Dash Is Illuminated DC plug DC plug is Charge interrupt is connected disconnected DC cord dis connected during charge cycle Light remains on Light comes on intermittently when vehicle is in use and when it is stopped No AC present Glows for 10 seconds Light
3. probe of multimeter set to 200 Q ohms on large terminal of solenoid with red wire attached and place black probe at blue wire position in the six pin connector on the key switch side Figure 11 10 Page 11 12 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 11 11 ELECTRICAL SYSTEM AND TESTING Circuit Testing Test Procedure 2 Key Switch Continued 200 DCV SETTING 200 Dey SETTING BATTERY BANK FOR DS CARRYALL I TOURALL AVETE XL AND FAIRWAY VILLAGER AAN BATTERY BANK FOR CARRYALL II CARRYALL VI RESORT VILLAGER TRANS PORTER TRANS SENDER AND ALL XL VEHICLES FRONT OF VEHICLE FRONT OF VEHICLE Figure 11 8 Battery Test Short Frame Vehicle READING SHOULD BE READING SHOULD BE LESS THAN 100 OHMS LESS THAN 100 OHMS TO THE POSITIVE POST ON BATTERY NUMBER 1 FORWARD AND REVERSE SWITCH GREEN WH WIRE RED WIRE SOLENOID 6 PIN CONNECTOR SOLENOID 200 2 SETTING Ja 200 Q SETTING WITH KEY SWITCH ON WITH KEY SWITCH ON Figure 11 10 Test Key Switch Multi step Potentiometer Vehicles Figure 11 11 Test Key Switch All Electric Vehicles 2 With the key switch OFF the reading should be no continuity If continuity is shown check the key switch wires and terminals and then replace defective parts 3 Insert the key and turn the switch ON The reading should b
4. Solenoid clicks when the key Accelerator Limit Switch Defective switch Test Procedure 4 Page 11 13 is turned on 2 Improper pedal adjustment Section 5 Brake Pedal Group CIRCUIT TESTING Read DANGER and WARNING on page 11 1 Using the following procedures the entire PowerDrive electrical system can be tested without major disas sembly of the vehicle CAUTION IF WIRES ARE REMOVED OR REPLACED MAKE SURE WIRING AND OR WIRING HARNESS IS PROPERLY ROUTED AND SECURED TO VEHICLE FRAME FAILURE TO PROPERLY ROUTE AND SECURE WIRING COULD RESULT IN VEHICLE MALFUNCTION PROPERTY DAMAGE OR PERSONAL INJURY e VEHICLES PRODUCED LATE IN THE 1999 MODEL YEAR MAY NOT HAVE A RUBBER BOOT ATTACHED TO THE 6 GAUGE RED WIRE AT THE SOLENOID CONTROL CIRCUIT Test Procedure 1 Batteries Voltage Check 1 With batteries connected and using a multimeter set to 200 volts DC place red probe on the posi tive post of battery No 1 and the black probe on the negative terminal of battery No 6 The multim eter should indicate at least 48 volts with the batteries fully charged If not check for loose battery connections or a battery installed in reverse polarity Refer to Section 13 Batteries for further details on battery testing Figures 11 8 or 11 9 Page 11 12 Test Procedure 2 Key Switch Vehicles with Multi step Wiper Switch Potentiometer 1 With batteries disconnected place red
5. remains on Hestore AC power Light will go out and charge will resume Check function 2 on CDM More than 75 Open circuit Batteries did EUs or 75 of load not receive full energy removed battery voltage charge but from batteries below 48 volts may be used Batteries did not receive adequate charge Charge ran 16 hours Recharge batteries Check batteries Section 13 Check charger Section 14 Check OBC Page 11 20 OBC is defective Replace OBC Figure 11 7 Battery Warning Diagnostic Chart 11 8 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement ELECTRICAL SYSTEM AND TESTING Troubleshooting Guide POWERDRIVE SYSTEM 48 TROUBLESHOOTING GUIDE SYMPTOM PROBLEM POSSIBLE CAUSES REFER TO 1 Vehicle will not operate Batteries Battery connections Test Procedure 1 Page 11 11 no solenoid click NL Batteries discharged Test Procedure 1 Page 11 11 Key Switch Test Procedure 2 Page 11 11 Failed switch Test Procedure 2 Page 11 11 F amp R Anti arcing Limit Test Procedure 3 Page 11 13 Switch Failed switch Test Procedure 3 Page 11 13 3 Cam is not activating switch Section 12 Electrical Compo nents F amp R Anti arcing Limit Switch Accelerator 1 Accelerator rod disconnected Section 5 Accelerator and Multi step Pot vehicles only Brake Pedal Accelerator Pedal Limit Test Procedure 4 Page 11 13 Switch 2 Disconnected or Figures 11 2
6. S1 motor terminal Meter should indicate continuity If continuity cannot be obtained and all wires and connections are correct replace F amp R switch Figure 11 20 Page 11 16 RED RING TERMINAL Ea T SOLENOID DIODE SETTING 2K Q SETTING Figure 11 15 Test Diode Figure 11 16 Test Activating Coil 200 Q SETTING MOTOR Figure 11 17 Test F amp R Forward Position Figure 11 18 Test F amp R Continuity Reverse Position Test Procedure 7 Solenoid Contacts Power Off 1 With batteries disconnected remove the yellow wire and red wire from the large posts of the solenoid Remove resistor assembly Place the red probe of the multimeter on one of the large posts of the solenoid and the black probe of the meter on the other large post on the solenoid Multimeter should indicate no continuity If multimeter indicates continuity replace solenoid Figure 11 21 Page 11 16 2 Using a multimeter check for resistance between both resistor terminals If reading is not approxi mately 250 ohms replace the resistor Figure 11 22 Page 11 16 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement 11 15 ELECTRICAL SYSTEM AND TESTING Circuit Testing CONTROLLER Figure 11 19 Test F amp R Reverse Position Figure 11 20 T
7. SPEED SWITCH RESISTOR ASSEMBLY IS IN GOOD CONDITION 5 f the resistance steps were not correct and the accelerator pedal is properly adjusted then replace multi step potentiometer 6 Replace wiper switch cover and reconnect six pin connector assembly Test Procedure 9 Continuously Variable Potentiometer 1 Disconnect the battery cables negative cable first and then disconnect the three pin connector from the main wire harness The connector emerges from under the front body floorboard Figure 11 25 Page 11 18 Turn key switch ON and place Forward Reverse handle in NEUTRAL 2 Connect Calibration Test Module CTM Club Car Part number 101887101 to the three pin connector using plug adapter Club Car Part Number 101984501 Figure 11 24 Page 11 17 3 Turn CTM ON Set mode switch to POT With accelerator pedal fully upright reading should be approx imately 3 62 volts 4 Press accelerator pedal to the floor Voltage reading should be volts If readings are not correct see Potentiometer Adjustment Procedure in Section 5 Accelerator and Brake Pedal in the appropriate Maintenance and Service Base Manual ALLIGATOR CLIP 18 GAUGE WHITE WIRE SEE TEST PROCEDURE 8 STEP 4 FOR OHM READINGS THREE PIN CONNECTOR MALE TERMINAL 18 GAUGE GREEN WIRE THREE PIN CONNECTOR je ADAPTER LCD DISPLAY WINDOW UPPER CALIBRATION SCREW m LOWER CALIBRATION SCREW CALIBRATION SCREWS 20K SETTING
8. Turn the CDM ON 2 Position the CDM on the seat bottom so it is aligned directly with the dash light LED Make sure the CDM infra red LED receiver is pointed at the dash light LED and there is a clear path between them NOTE IF BY POSITIONING GDM ON SEAT BOTTOM CDM IS UNABLE TO COLLECT DATA STREAM FROM OBC HOLD CDM APPROXIMATELY 6 IN FROM DASH LIGHT Wait approximately 30 seconds for a value to appear in the display window 4 If a value does not appear in the display window after 30 seconds try adjusting the aim of the CDM and repeating step 3 until a value appears If there is still no reading check for weak batteries in the CDM Once a value has been obtained in the display window the CDM may be removed from its receiving position and the data reviewed The CDM will hold the values for F1 F2 F3 and F4 until the CDM is turned OFF or it receives another line of data Use the following procedure to review the data stored in the CDM 1 The value currently displayed will be F1 battery voltage 2 view F2 press and hold the button on the CDM When 2 appears in the display window release the button The value for F2 will then be displayed 3 To view press and hold the button on the CDM until Func 3 appears in the display window Release the button The value for will be displayed 4 To view F4 press and hold the button on the CDM until Func 4 appears in the display window Release th
9. through 11 6 improperly connected wires Pages 11 3 through 11 7 Failed switch Test Procedure 4 Page 11 13 Solenoid Test Procedure 5 Page 11 14 Failed coil Test Procedure 5 Page 11 14 Failed solenoid diode Test Procedure 5 Page 11 14 Controller Electrical Leakage Onboard Computer 1 j Dirt or acid residue on the Test Procedure 10 Page 11 controller 18 Battery connections Figure 11 1 Page 11 2 Onboard computer solenoid Test Procedure 11 Page 11 lockout failure 20 2 Vehicle will not operate Batteries Battery connections Test Procedure 1 Page 11 11 solenoid clicks i Batteries discharged Test Procedure 1 Page 11 11 j Pages 11 3 through 11 7 Failed contacts Potentiometer 1 Loose wires Figures 11 2 through 11 6 Pages 11 3 through 11 7 2 Improperly wired Figures 11 2 through 11 6 Pages 11 3 through 11 7 3 Short or open circuit Test Procedures 8 or 9 pages 11 16 and 11 17 4 Improperly adjusted Section 5 Accelerator amp Brake Pedal Controller Test Procedure 10 Page 11 18 Defective Controller Test Procedure 10 Page 11 18 2 Open shorted Section 15 Motor windings 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 11 9 Solenoid 6 ELECTRICAL SYSTEM AND TESTING Troubleshooting Guide POWERDRIVE SYSTEM 48 TROUBLESHOOTING GUIDE SYMPTOM PROBLEM POSSIBLE CAUSES REFER REFERTO 3 Vehicle runs slowly Improper
10. 5 4 With diode assembly and yellow wire removed from the small activating coil post of the solenoid place red probe of the multimeter on the post Place the black probe on the other small activating coil post on the solenoid A reading of 190 to 250 ohms should be obtained If not replace the solenoid If the ohm reading is correct reconnect the diode assembly and yellow wire Figure 11 16 Page 11 15 POWER CIRCUIT Test Procedure 6 Forward Reverse F amp R Switch 1 Disconnect batteries and use a multimeter set to 200 Q to test the F amp R switch in both directions With Forward Reverse handle in FORWARD place red probe of multimeter on M terminal of speed controller and place black probe on S1 motor terminal Meter should indicate continuity Figure 11 17 Page 11 15 2 With Forward Reverse handle in FORWARD place red probe on A2 motor terminal and place the black probe on the S2 motor terminal Meter should indicate continuity Figure 11 18 Page 11 15 Page 11 14 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement ELECTRICAL SYSTEM AND TESTING Circuit Testing 3 With Forward Reverse handle in REVERSE place red probe on speed controller M terminal and place black probe on S2 motor terminal Meter should indicate continuity Figure 11 19 Page 11 16 4 With Forward Reverse handle in REVERSE place red probe on the A2 motor terminal and the black probe on the
11. AND TESTING Electrical Circuits KEY SWITCH REVERSE BUZZER FORWARD REVERSE SWITCH WARNING LIGHT MULTI STEP POTENTIOMETER L SIX PIN CONNECTOR 3LIHM AONVYO FUSE AND RECEPTACLE MOTIAA BATTERY BANK MOTI3A THREE PIN CONNECTOR ONBOARD COMPUTER Figure 11 2 Wiring Diagram DS Electric Vehicle 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 11 3 ELECTRICAL SYSTEM AND TESTING Electrical Circuits KEY SWITCH FORWARD REVERSE REVERSE SWITCH BUZZER WARNING LIGHT MULTI STEP POTENTIOMETER Ws SN 2 ADNVYO FUSE AND RECEPTACLE Jdlaufid BATTERY add MOTI3A MOTT3JA 90189 C N3349 5 co THREE PIN CONNECTOR ONBOARD COMPUTER MOTOR Figure 11 3 Wiring Diagram Tourall Carryall Page 11 4 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement ELECTRICAL SYSTEM AND TESTING Electrical Circuits i ONBOARD COMPUTER CONTINUOUSLY VARIABLE POTENTIOMETER MOTI3A N343u9 M 2222 180 LIMIT SWITCHES FUSE AND RECEPTACLE BATTERIES Figure 11 4 Wiring Diagram Carryall Il 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
12. ERIES NEGATIVE CABLE FIRST AS SHOWN IN FIGURE 11 1 PAGE 11 2 AND THEN DISCHARGE THE CONTROLLER AS FOLLOWS TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD REVERSE HANDLE IN THE REVERSE POSITION SLOWLY DEPRESS THE ACCELERATOR PEDAL AND KEEP IT DEPRESSED UNTIL THE REVERSE WARNING BUZZER CAN NO LONGER BE HEARD WHEN THE BUZZER STOPS SOUNDING THE CONTROLLER IS DISCHARGED GENERAL INFORMATION The PowerDrive System 48 vehicle uses a 48 volt electrical system that is powered by six 8 volt lead acid batteries and includes an onboard computer The PowerDrive System 48 vehicle uses a series wound motor which increases or decreases the current flow amperage through the armature and field coils at the same rate Vehicles that incorporate the PowerDrive System 48 include 1 DS electric golf car 2 Fairway Villager electric Tourall electric 4 Carryall I Il and VI electric models and 5 Trans Porter Trans Sender and Resort Villager electric models 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement 11 1 ELECTRICAL SYSTEM AND TESTING Electrical Circuits BATTERY BANK FOR DS CARRYALL I TOURALL BATTERY BANK FOR CARRYALL Il CARRYALL VI RESORT VILLAGER TRANS PORTER AND FRONT OF VEHICLE FRONT FAIRWAY VILLAGER e TRANS SENDER REMOVE NEGATIVE CABLE FIRST DISCONNECT DISCONNECT NEGATIVE BATTERY CABLES HERE BATTERY CABLES HERE CABLE FIRST Figure 11 1 Ba
13. EST PROCEDURE 15 WIRES CORREGILY WIRES INCORRECTLY CONNEGTED CONNECTED CHECK CONTINUITY RECONNECT WIRES OF CIRCUIT WIRES TO REVERSE BUZZER TEST PROCEDURE 16 NO CONTINUITY CONTINUITY REPLACE WIRE REPLACE REVERSE BUZZER Figure 11 32 Reverse Buzzer Will Not Function THE COMMUNICATION DISPLAY MODULE CDM The CDM can be used io retrieve from the onboard computer four important items of information that can be useful in troubleshooting an electric vehicle with PowerDrive System 48 To access one of these items the item s corresponding Function Code must be selected on the CDM This is done by pressing the Function Button until the desired function code is displayed in the window See Figure 11 33 Page 11 25 for CDM features Releasing the button when the desired code is displayed will display the data Function codes and corresponding data are as follows F1 Battery voltage This displays the battery pack s current state of charge A reading of less than 48 volts indicates the batteries need to be charged If a reading of less than 48 volts is obtained immediately after a charge cycle there may be a problem in the charge circuit 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 11 23 ELECTRICAL SYSTEM AND TESTING The Communication Display Module CDM CDM Continued F2 Energy units removed since last charge cycle If the display reads over 75 the vehicle Battery Trouble Light shou
14. INS ETC BEFORE SERVICING VEHICLE ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CONNECTIONS TO AVOID UNINTENTIONALBY STARTING THE VEHICLE DISCONNECT BATTERIES AS SHOWN IN FIGURE 12 1 PAGE 12 2 AND THEN DISCHARGE THE CONTROLLER AS FOLLOWS TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD REVERSE HANDLE IN THE REVERSE POSITION SLOWLY DEPRESS THE ACCELERATOR PEDAL AND KEEP IT DEPRESSED UNTIL THE REVERSE WARNING BUZZER CAN NO LONGER BE HEARD WHEN THE BUZZER STOPS SOUNDING THE CONTROLLER IS DISCHARGED CAUTION IF WIRES ARE REMOVED OR REPLACED MAKE SURE WIRING AND OR WIRING HARNESS IS PROPERLY ROUTED AND SECURED TO VEHICLE FRAME FAILURE TO PROPERLY ROUTE AND SECURE WIRING COULD RESULT IN VEHICLE MALFUNCTION PROPERTY DAMAGE OR PERSONAL INJURY 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 12 1
15. SECTION 11 ELECTRICAL SYSTEM AND TESTING DANGER e BATTERY EXPLOSIVE GASES DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY VENTILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE ALWAYS WEAR FULL FACE SHIELD WHEN WORKING ON OR NEAR BATTERIES USE EXTREME CAUTION WHEN USING TOOLS WIRES OR METAL OBJECTS NEAR BATTERIES A SHORT CIRCUIT AND OR SPARK COULD CAUSE AN EXPLOSION BATTERY POISON CONTAINS ACID CAUSES SEVERE BURNS AVOID CONTACT WITH SKIN EYES OR CLOTHING ANTIDOTES EXTERNAL FLUSH WITH WATER CALL A PHYSICIAN IMMEDIATELY INTERNAL DRINK LARGE QUANTITIES OF MILK OR WATER FOLLOW WITH MILK OF MAGNESIA OR VEGETABLE OIL CALL A PHYS CIAN IMMEDIATELY EYES FLUSH WITH WATER FOR FIFTEEN MINUTES CALL PHYSICIAN IMMEDIATELY A WARNING AN AD e ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNING STATEMENTS IN THIS MANUAL WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE TURN KEY SWITCH OFF PLACE FORWARD REVERSE HANDLE IN THE NEUTRAL POSITION AND REMOVE KEY PRIOR TO SERVICING DO NOT WEAR LOOSE GLOTHING REMOVE JEWELRY SUCH AS RINGS WATCHES CHAINS ETC BEFORE SERVICINGWERICLE USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CONNECTIONS TO AVOID UNINTENTIONALLY STARTING THE VEHICLE DISCONNECT BATT
16. Supplement Page 11 25 the WARNING on page 11 1 After a short time replace the lead and restart the OBC SECTION 12 ELECTRICAL COMPONENTS 12 DANGER e BATTERY EXPLOSIVE GASES DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY VENTILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE ALWAYS WEAR FULL FACE SHIELD WHEN WORKING ON OR NEAR BATTERIES USE EXTREME CAUTION WHEN USING TOOLS WIRES OR METAL OBJECTS NEAR BATTERIES A SHORT CIRCUIT AND OR SPARK COULD CAUSE AN EXPLOSION BATTERY POISON CONTAINS ACID CAUSES SEVERE BURNS AVOID CONTACT WITH SKIN EYES OR CLOTHING ANTIDOTES EXTERNAL FLUSH WITH WATER CALL A PHYSICIAN IMMEDIATELY INTERNAL DRINK LARGE QUANTITIES OF MILK OR WATER FOLLOW WITH MILK OF MAGNESIA OR VEGETABLE OIL CALL A PHYSICIAN IMMEDIATELY EYES FLUSH WITH WATER FOR FIFTEEN MINUTES CALL PHYSICIAN IMMEDIATELY A WARNING ANA e ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNING STATEMENTS IN THIS MANUAL ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES TURN KEY SWITCH OFF PLACE FORWARD REVERSE HANDLE IN THE NEUTRAL POSITION AND REMOVE KEY PRIOR TO SERVICING DO NOT WEAR LOOSE CLOTHING REMOVE JEWELRY SUCH AS RINGS WATCHES CHA
17. e button The value for F4 will be displayed NOTE e THE VALUES OF ALL FOUR FUNCTIONS CAN BE RECALLED BY PRESSING AND RELEASING THE CDM BUTTON 11 24 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement ELECTRICAL SYSTEM AND TESTING CDM Troubleshooting Guide DISPLAY LOW BATTERY WINDOW INDICATOR COMMUNICATION 4 DISPLAY MODULE LOW BATTERY DISPLAY FUNCTIONS RELEASE BUTTON TO SHOW FUNCTION VALUE ca Eie Meade since last charge cycle e FU N CTIO N Noto BUTTON rge accumulated energy units removed ast charge termination type 0 No Histo 1 Incomplete 2 DVDT 4 Normal 8 Max timer PART 17075 Figure 11 33 CDM CDM TROUBLESHOOTING GUIDE Use this chart as a starting point for troubleshooting problems with communications between the CDM and onboard computer Contact your local Club Car representative for more comprehensive information OBC Will Not Communicate With The CDM Defective Dash Light Dead CDM battery Replace CDM battery Defective CDM unit Defective OBC Replace CDM Replace OBC OBC program is locked up OBC is in a More than 75 powerdown mode EUs or 75 of Remove battery lead and discharge the speed controller See the instructions in energy removed from batteries Restart OBC by driving vehicle or by connecting charger DC plug Recharge Batteries 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service
18. e continuity less than 100 ohms 4 f the reading is incorrect check the key switch wires and terminals and then replace defective parts 5 Reconnect six pin connector 6 Place red probe of multimeter on large terminal of solenoid with red wire attached and place black probe at green white wire from the Forward Reverse limit switch No 1 Figure 11 11 Page 11 12 7 Depress and hold the accelerator pedal to activate the accelerator pedal limit switch 8 With the key switch OFF the reading should be no continuity 9 Insert key and turn switch ON while continuing to depress accelerator pedal Reading should be continuity less than 100 ohms 10 If reading is incorrect check accelerator limit switch wires and terminals and replace defective parts Page 11 12 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement ELECTRICAL SYSTEM AND TESTING Circuit Testing Vehicles with Continuously Variable Potentiometer 1 Place red probe of multimeter on large terminal of solenoid with red wire attached and place black probe at green white wire from the Forward Reverse limit switch No 1 Figure 11 11 Page 11 12 Depress and hold the accelerator pedal to activate the accelerator pedal limit switch With the key switch OFF the reading should be no continuity less than 100 ohms Insert key and turn switch ON while continuing to depress accelerator pedal Reading should be continuity If the read
19. ed from Half speed Reverse Limit Switch Resistance should measure approximately 5100 ohms 410 Figure 11 31 Page 11 22 FORWARD AND REVERSE FORWARD AND REVERSE PROCEDURE 12 Sven STEP 2 FOR READING SWITCH BLACK WIRE Sg WITH RESISTOR 9 e 3 BLACK WIRE N WITH RESISTOR 20K SETTING SIX PIN CONNECTOR 200 SETTING Figure 11 30 Test Half Speed Reverse Limit Switch Figure 11 31 Test Half Speed Reverse Resistor Vehicles with Continuously Variable Potentiometer 2 1 Disconnect the three pin connector connects the potentiometer to the Forward Reverse wire har ness from the Forward Reverse wire harness The connector emerges from under the front body floorboard Figure 11 25 Page 11 18 2 2 With a multimeter set to 20 ohms measure the resistance through the 18 gauge black wire from the Forward Reverse wire harness at disconnect from three pin connector to the end disconnected from the Half speed Reverse Limit Switch Resistance should measure approximately 5100 ohms 10 If the meter reading is not correct replace the wire assembly to the limit switch Test Procedure 14 Reverse Buzzer Limit Switch 1 Disconnect the battery cables negative cable first and then disconnect red white wire and orange wire from limit switch located on ihe F amp R switch assembly 2 Connect black probe of a multimeter to top terminal of limit switch and connect red probe to the bot
20. ervice Supplement ELECTRICAL SYSTEM AND TESTING Circuit Testing 6 Bypass the OBC solenoid lockout circuit to isolate the problem Use the following procedure 6 1 Make sure the batteries are disconnected as shown Figure 11 1 Page 11 2 and the controller has been discharged See instructions in the WARNING on page 11 1 6 2 Connect one end of a jumper wire to the small coil post of the solenoid with 18 gauge yellow wire attached Connect the other end of the jumper wire to the negative post of battery No 6 6 3 Reconnect the batteries positive cable first and tighten terminals to 110 in lb 12 4 N m 6 4 If vehicle can be driven with jumper wire attached then OBC has failed and must be replaced If vehicle cannot be driven with jumper wire attached then refer to the Troubleshooting Guide on pages 11 8 through 11 11 HALF SPEED REVERSE Cb COMPUTER LIMIT SWITCH FOR 1998 VEHICLES F amp R No 3 i pr UN d CAUTION NEGATIVE BATTERY VOLTAGE ON BOARD COMPUTER mfd by LESTER ELECTRICAL PART NO 19190 88 Ain ONLY WITH CLUB CAR POWER DRIVE aA ARGERS ON 48 VDC 24 CELL BATTERY SYSTEM HALF SPEED REVERSE LIMIT SWITCH FOR 1999 LE9805502800 PATENT PENDING VEHICLES F amp R No 3 Figure 11 28 OBC V 1 35P Figure 11 29 F amp R Limit Switch Test Procedure 12 Half speed Reverse Limit Switch F amp R Limit Switch No 3 1 With batteries disconnected check for proper wiring and tight connec
21. est F amp R Continuity Reverse Position SPEED CONTROL CIRCUIT Test Procedure 8 Multi step Potentiometer 1 Disconnect the battery cables negative cable first and then disconnect the six pin connector at multi step potentiometer Remove switch cover by pressing down on locking tabs 2 With multimeter set for 20K ohms connect black lead of multimeter to purple wire terminal end located in six pin connector on potentiometer Connect red probe to yellow wire terminal end Fig ure 11 23 Page 11 17 RESISTOR 200 Q SETTING 27 2K SETTING SOLENOID Figure 11 21 Test Solenoid Contacts Figure 11 22 Test Resistor 3 Depress the accelerator pedal until wiper switch movable contact is on third stationary contact Multim eter should register approximately 565 ohms 4 Measure resistance while depressing the accelerator pedal The measured resistance should increase incrementally in six steps 1st Step 910 ohms approx 2nd Step 1660 ohms approx 3rd Step 2570 ohms approx Page 11 16 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement ELECTRICAL SYSTEM AND TESTING Circuit Testing 4th Step 3570 ohms approx oth Step 4570 ohms approx 6th Step 5570 ohms approx e IF AN INCREASE IN RESISTANCE FROM 0 TO APPROXIMATELY 5000 OHMS IS OBTAINED WHEN THE ACCELERATOR PEDAL IS DEPRESSED WITHOUT EXCEEDING APPROXIMATELY 7000 OHMS THEN THE
22. ide Figure 11 13 Page 11 14 2 With the accelerator pedal fully up not depressed the reading should be no continuity With the key switch OFF depress the accelerator pedal The reading should be continuity 4 If readings for steps 2 and are not correct check wire connection at the normally closed NC common COM terminals of accelerator pedal limit switch located inside wiper switch Check accelerator pedal adjust ment See Section 5 Accelerator and Brake Pedal 5 f wires are connected correctly and accelerator pedal is properly adjusted but readings are still not correct replace limit switch 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 11 13 ELECTRICAL SYSTEM AND TESTING Circuit Testing Vehicles with Continuously Variable Potentiometer 1 With batteries disconnected controller discharged and the key switch in the ON position connect the red lead of a multimeter set for 200 ohms to the large post of the solenoid with 6 gauge red wire attached and connect the black lead of the multimeter to the green white wire from limit switch No 1 on the Forward Reverse switch Figure 11 14 Page 11 14 1 1 With the accelerator pedal fully upright not depressed the reading should be no continuity 1 2 With the accelerator pedal depressed the reading should be continuity 2 lf these readings are not obtained check to be sure that the wires are connected properly to the nor
23. ing is incorrect check the key switch accelerator limit switch wires and terminals and replace defective parts amp Test Procedure 3 Forward Reverse Anti Arcing Limit Switch NOTE e THERE ARE THREE LIMIT SWITCHES ON THE FORWARD REVERSE SWITCH THE FORWARD REVERSE ANTI ARCING LIMIT SWITCH IS THE ONE CLOSEST TO THE VEHICLE BODY FORWARD AND REVERSE SWITCH WHITE BLACK WIRE Figure 11 12 F amp R Anti Arcing Limit Switch 1 With batteries disconnected place the red probe of the multimeter set for 200 ohms on the small acti vating coil post of the solenoid that has the white black and red wires connected Place the black probe on the 1 anti arcing limit switch at the normally open NO terminal Figure 11 12 Page 11 13 2 Heading should show continuity when Forward Reverse handle is placed in either FORWARD or REVERSE and no continuity when in NEUTRAL and when in FORWARD or REVERSE until the rotor contacts are in contact with contact bars If not check wires and terminals If readings are still incorrect replace switch Test Procedure 4 Accelerator Pedal Limit Switch Vehicles with Muiti step Wiper Switch Potentiometer 1 With batteries disconnected place black probe of multimeter set for 200 ohms on green white wire terminal from six pin connector on the wiper switch side and red probe at the blue wire position at the six pin connector on wiper switch s
24. ld be illuminated the vehicle batter ies need to be recharged before being used again This data can be used to make sure all vehicles in a fleet receive equal usage on a short term basis F3 Total accumulated energy units removed since initial vehicle start up This information is useful to make sure all vehicles in a fleet receive equal usage over long periods of time F4 Last charge termination type 1 incomplete 2 DVDT 4 normal 8 max timer A 1 2 4 or 8 will be displayed 1 Indicates the last charge cycle was incomplete and the batteries were not fully charged Batteries should be charged again at the earliest opportunity 2 Indicates a back up charge program was employed by the OBC to complete the charge cycle A DVDT charge may be displayed the first few times a new set of batteries Is charged also the first time a set of batteries is charged after the batteries have been disconnected and reconnected problem may exist if persistent DVDT readings are obtained 4 Indicates the last charge cycle was normal 8 Indicates the charger ran for sixteen hours and shut down without completing the charge cycle This means there may be a problem in the charge circuit The CDM also has a low battery signal which indicates when batteries are weak and need changing Weak batter ies in the CDM may cause CDM to register inaccurate information or no information USING THE CDM TO RETRIEVE DATA FROM THE ONBOARD COMPUTER 1
25. ly wired 11 2 through 11 6 Pages 11 3 through 11 7 Batteries Loose terminals or corrosion Test Procedure 1 and Section 13 Batteries 2 Improperly wired Test Procedure 1 and Section 13 Batteries 3 Batteries failed Test Procedure 1 and Section 13 Batteries 4 Batteries not fully charged Test Procedure 1 and Batteries Section 13 Defective motor Section 15 Motor Potentiometer 1 Improperly adjusted Test Procedures 8 and 9 page 11 16 and 11 17 2 Defective potentiometer Test Procedures 8 and 9 page 11 16 and 11 17 Half speed Reverse Limit Failed in the closed position Test Procedure 12 Page 11 21 Switch i 2 Improperly wired Figures 11 2 through 11 6 Pages 11 3 through 11 7 Controller 1 Vehicle overload Let controller cool remove part of load Defective controller controller Test Procedure 10 Page 11 18 Procedure 10 Test Procedure 10 Page 11 18 11 18 bi Dragging brakes Section 6 Brakes Under inflated or flat tires Section 8 Wheels and Tires 8 Wheels and Tires Vehicle runs full speed in Forward Reverse Half speed Loose or disconnected wires Sesion Snes andes 12 Electrical Compo reverse Reverse Limit Switch nents Failed switch Section 12 Electrical Compo nents Half speed 5100 ohm Resis 1 Resistor is disconnected or Test Procedure 13 Page 11 tor has failed 21 Vehicle will run in forward but Forward Reve
26. mally open NO and common COM terminals of the accelerator pedal limit switch located on the con tinuously variable potentiometer Check accelerator pedal adjustment See Section 5 Accelerator and Brake Pedal for information regarding accelerator and brake peda adjustment 3 If wires are connected correctly and accelerator pedal is properly adjusted but readings are incorrect replace accelerator pedal limit switch GREEN WHITE WIRE RED WIRE SOLENOID 200 Q SETTING 200 SETTING WITH PEDAL UP Figure 11 13 Test Limit Switch Multi step Figure 11 14 Test Limit Switch Cont Variable Test Procedure 5 Solenoid Activating Coil 1 With batteries disconnected remove the diode terminal end from the small post on the solenoid with 18 gauge yellow wire attached 2 Make sure that the diode direction is correct Figures 11 2 through 11 6 Pages 11 3 through 11 7 The red terminal end of the diode attaches to the small post on the solenoid with 18 gauge red wire and 18 gauge white black striped wire attached 3 Using a multimeter sei for diode check for continuity between both diode terminals Reverse the tester leads and again check for continuity A diode is designed to conduct current in one direction only If a diode shows continuity in both directions or does not show continuity in either direction replace the diode assembly Figure 11 15 Page 11 1
27. mportant that the controller terminal face be free of dirt and debris to help prevent electrical leakage that could cause faulty operation 2 Check for solenoid input 11 18 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement ELECTRICAL SYSTEM AND TESTING Circuit Testing A WARNING e LIFT ONLY ONE END OF THE VEHICLE AT A TIME BEFORE LIFTING UNLOAD THE CARGO BED 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 2 1 Disconnect the batteries negative cable first and discharge the controller as instructed in the WARNING on page 11 1 Figure 11 1 Page 11 2 Remove the 6 gauge white wire from the A2 motor terminal and secure wire so it will not make contact with any live components or connec tions Reconnect batteries positive cable first Figure 11 1 Page 11 2 2 2 Place Forward Reverse handle in either FORWARD or REVERSE turn key to ON and depress acceler ator pedal until limit switches activate This should cause solenoid to operate with an audible click 2 3 Connect multimeter set to 200 volts DC across solenoid small activating posts Multimeter should read full battery voltage when accelerator is depressed to the floo
28. r 3 Check for controller input voltage 3 1 Place Forward Reverse handle in either FORWARD or REVERSE turn key ON and depress accelera tor pedal until limit switches activate This should cause solenoid to operate with an audible click 3 2 Remove the 18 gauge red wire from controller input terminal 1 3 3 Place multimeter set for 200 volts DC black probe on B terminal of controller with 6 gauge black wire attached and red probe into terminal end of red wire removed from controller terminal 1 Mul timeter should indicate full battery voltage with accelerator pedal pressed to floor Figure 11 26 Page 11 18 3 4 If the controller input terminal isnot getting full battery voltage then check wire and connections between the solenoid small post and controller 1 terminal Replace defective parts 3 5 Disconnect battery wires negative cable first Figure 11 1 Page 11 2 and discharge the control ler as instructed in ihe WARNING on page 11 1 Reconnect the 6 gauge white wire to the A2 motor terminal Reconnect batteries 4 Check for controller output 4 1 Disconnect battery wires Remove 6 gauge white wire from A2 motor terminal and secure wire so that it cannot make contact with any live components or connections Reconnect battery wires 4 2 Connect the multimeter set for 200 volts DC red probe to the controller B terminal and the black probe to the controller M terminal The multimeter should display appro
29. robe on the A2 terminal reading should indicate continuity Reverse leads and read ing should indicate no continuity 5 4 Reconnect wires to controller B terminal Reconnect batteries positive cable first Figure 11 1 Page 11 2 Test Procedure 11 Onboard Computer Lockout Circuit For vehicles with charger receptacles follow step 1 1 Inspect the charger receptacle for water in the contacts If water is found proceed as follows e IF BATTERY PACK IS WET MAKE SURE 18 GAUGE GRAY WIRE FROM OBC 15 NOT TOUCHING BATTERIES WIRE TIE THE 18 GAUGE GRAY LEAD AND 18 GAUGE GRAY WIRE TO WIRE HARNESS IF NECESSARY 1 1 Disconnect the batteries negative cable first as shown Figure 11 1 Page 11 2 1 2 Discharge the controller See instructions in the WARNING on page 11 1 1 3 Remove the receptacle from the vehicle See Section 12 Electrical Components 1 4 Dry receptacle by wiping with a clean dry cloth and by blowing into contacts with compressed air 1 5 Reinstall the charger receptacle 2 With batteries disconnected inspect the sense lead fuse in the gray wire from OBC Using a multimeter set to 200 Q check fuse for continuity If Continuity is present fuse is good If no continuity is present fuse is blown Replace the fuse if blown It is possible the OBC can become locked up causing the OBC solenoid lockout circuit to malfunc tion If this conditionis suspected restart the computer as follows 3 1 Disconnect
30. rse Anti arcing Loose or broken wires Test Procedure 3 and not in reverse or will run in Limit Switch Section 12 Electrical Compo reverse but not forward nents Improper actuation of switch Test Procedure 3 and Section 12 Electrical Compo nents Improperly wired Test Procedure 3 and Section 12 Electrical Compo nents Forward Reverse 1 Poor continuity of switch Test Procedure 6 Page 11 14 Switch contacts 6 Vehicle not being fully Charger Connections 1 Loose wires at receptacle or Section 14 PowerDrive charged batteries Charger Charger 1 Incorrect incoming AC volt Section 14 PowerDrive age Charger 2 Charger output is low Section 14 PowerDrive Charger 3 Charger cord and plugs Section 14 PowerDrive Charger Page 11 10 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement ELECTRICAL SYSTEM AND TESTING Circuit Testing POWERDRIVE SYSTEM 48 TROUBLESHOOTING GUIDE SYMPTOM PROBLEM POSSIBLE CAUSES REFER TO 6 Vehicle not being fully Charger Continued Charger relay Section 14 PowerDrive charged continued Charger Charger fuse is blown Section 14 PowerDrive Charger Charger Onboard Computer 1 Improper charging Section 14 PowerDrive Charger Vehicle runs without pressing Accelerator 1 Improper pedal adjustment Section 5 Accelerator and the accelerator when the key Brake Pedal Group is on and the Forward Reverse Switch is in forward or reverse
31. the batteries negative cable first as shown Figure 11 1 Page 11 2 and discharge the controller See instructions in the WARNING on page 11 1 3 2 Reconnect the batteries positive cable first and tighten terminals to 110 in lb 12 4 N m Drive the vehicle If the problem has been corrected the vehicle will function normally e A CHANGE IN THE DESIGN OF THE OBC RESULTED IN THE INCORPORATION OF A FIELD EMITTING TRANSISTOR FET PROTECTION SYSTEM WITHIN THE SOLENOID LOCKOUT CIRCUIT THIS PROTECTS THE FET FROM BEING BLOWN AND ALLOWS IT TO BE RESET THE NEW OBC S ARE MARKED WITH THE NUMBER V1 35P ON THE LABEL FIGURE 11 28 PAGE 11 21 VEHICLES WITH SERIAL NUMBERS 9841 703262 AND GREATER ARE EQUIPPED WITH THIS NEW FET PROTECTION SYSTEM Vehicles with serial numbers 9841 703262 and greater proceed to step 4 Vehicles with serial num bers lower than 9841 703262 proceed to step 5 4 Disconnect battery cables negative cable first and inspect wire terminals Make sure wire terminals are not touching corresponding solenoid terminal posts Reconnect battery cables and attempt to drive the vehicle 5 f vehicle cannot be driven disconnect battery cables and solenoid Remove and replace solenoid diode reconnect solenoid making sure wires are correctly positioned reconnect battery cables and attempt to drive the vehicle If vehicle still does not respond proceed with step 6 Page 11 20 1998 1999 PowerDrive System 48 Vehicle Maintenance and S
32. tions 2 Using a multimeter set to 200 ohms check continuity across common COM and normally open NO and across common COM and normally closed NC Figures 11 29 and 11 30 Pages 11 21 and 11 22 With the limit switch lever up not depressed readings should be COM to NC Zero or continuity tester is illuminated COM to NO Infinity or continuity tester is not illuminated With the limit switch lever depressed readings should be COM to NC Infinity or continuity tester is not illuminated COM to NO Zero or continuity tester is illuminated 3 If meter readings are not correct replace limit switch Test Procedure 13 Half speed Reverse Resistor 1 Disconnect the batteries negative cable first and then disconnect black lead from half speed reverse limit switch located on Forward Reverse switch Figure 11 31 Page 11 22 2 Measure resistance Vehicles with Multi step Potentiometer 2 1 Disconnect the six pin connector which connects the multi step potentiometer to the Forward Reverse wire harness Figure 11 2 Page 11 3 or Figure 11 3 Page 11 4 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 11 21 ELECTRICAL SYSTEM AND TESTING Circuit Testing Test Procedure 13 Half speed Reverse Resistor Continued 2 2 With multimeter set to 20K ohms measure resistance through 18 gauge black wire from Forward Reverse wire harness at disconnect from six pin connector to end disconnect
33. tom terminal With F amp R switch handle in NEUTRAL or FORWARD reading should be no continuity Place F amp R switch handle in REVERSE and reading should be continuity If readings are not correct replace limit switch Test Procedure 15 Reverse Buzzer Wire Connections Use the following flow chart Figure 11 32 Page 11 23 as a starting point for troubleshooting the reverse buzzer circuit Make sure batteries are disconnected 1 The red 18 gauge wire should be connected to the terminal of the reverse buzzer The orange 18 gauge wire should be connected to the terminal on the reverse buzzer Test Procedure 16 Wire Continuity 1 Disconnect the battery cables negative cable first and then disconnect one end of the wire to be tested and connect probe of multimeter to each end of the wire Multimeter should indicate continuity If reading is incorrect repair or replace wire 11 22 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement ELECTRICAL SYSTEM AND TESTING The Communication Display Module CDM REVERSE BUZZER WILL NOT FUNCTION REVERSE BUZZER REVERSE BUZZER WILL NOT FUNCTION AND WILL NOT FUNCTION AND VEHICLE WILL NOT RUN VEHICLE RUNS CHECK BATTERIES CHECK REVERSE BUZZER TEST PROCEDURE 1 LIMIT SWITCH TEST PROCEDURE 14 USE MULTIMETER TO TEST LIMIT SWITCH CORRECT INGORRECT CONTINUITY READING CONTINUITY READING CHECK WIRE CONNECTION REPLACE LIMIT SWITCH TO THE REVERSE BUZZER T
34. ttery Configuration ELECTRICAL CIRCUITS There are four separate circuits which make up the electrical system of the PowerDrive System 48 vehicle 1 the control circuit 2 the power circuit 3 the speed control circuit and 4 the charge circuit A reverse buzzer is also included on every vehicle CONTROL CIRCUIT The control circuit consists of 1 Key switch 2 Forward Reverse F amp R anti arcing limit switch 3 Accelerator limit switch 4 Solenoid Activating Coil POWER CIRCUIT The power circuit consists of 1 Solid state speed controller 2 Solenoid contacts 3 F amp H switch 4 Motor SPEED CONTRO CIRCUIT For models with a multi step potentiometer the speed control circuit consists of the multi step potentiometer with discrete resistors For models equipped with a continuously variable potentiometer the speed control circuit includes a solid state potentiometer CHARGE CIRCUIT The charge circuit includes the onboard computer battery charger DC charger plug charger receptacle receptacle fuse link Trans porter Trans sender and Carryall VI vehicles with onboard chargers will not have a charger receptacle or receptacle fuse link and the 8 volt batteries The onboard fuse link provides addi tional protection to the vehicle charging circuit The fuse is rated for use with the Club Car PowerDrive charger only 11 2 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement ELECTRICAL SYSTEM
35. ximately 48 volts which is coniroller capacitor voliage Figure 11 27 Page 11 18 4 3 Turn key switch ON place Forward Reverse handle in FORWARD and watch multimeter as you depress the accelerator pedal With the accelerator pedal fully depressed the multimeter should indicate full battery voltage If the multimeter reading does not rise to full battery voltage with a properly functioning potentiometer and correct pedal adjustment then the controller is defective 4 4 Discharge the controller as instructed in WARNING on page 11 1 Attach the 6 gauge white wire to the A2 motor terminal Reconnect batteries positive cable first Figure 11 1 Page 11 2 For 48 Volt vehicles excluding the DS 5 Check for diode 5 1 Disconnect battery wires as shown Figure 11 1 Page 11 2 and discharge controller as instructed in WARNING on page 11 1 1998 1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 11 19 ELECTRICAL SYSTEM AND TESTING Circuit Testing Test Procedure 10 Solid State Speed Controller Continued 5 2 Using two wrenches to keep the posts from turning remove wires from controller B terminal 5 3 Use a multimeter set to Diode to test the resistance between the controller A2 and B terminals This test is for the presence of a functioning diode inside the controller If the diode is shorted either open or closed the controller is defective With the black probe on the B terminal and the red p
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