IGNTITION CIRCUIT TESTING LEAD ACID

Ignition Circuit Wiring diagram

Test #1

Measure voltage between pin#1 pin#12 of DC/DC converter 12 pin connector. Connector can be unplugged for this test. Should measure battery pack voltage which is typically about 80 volts DC.

If so, see test #2.

If not see test #12

Test #2

Measure voltage between pin#4, 5 or 6 pin#9 or 10 of DC/DC converter 12 pin connector. Connector must be plugged in for this test. Should measure about 13.5 volts DC.

If so, see test #3

If not, dc/dc converter is bad. Replace and retest.

Test #3

Measure voltage between pins #4, 5 or 6 pin #3 of DC/DC converter 12 pin connector. Connector must be plugged in for this test. Ignition key needs to be in the on position. Should measure about 13.5 volts DC.

If so, see test #4

If not, see test #5

Test #4

Measure voltage between pin #4, 5 or 6 pin #7 or 8 of DC/DC converter 12 pin connector. Connector must be plugged in for this test. Ignition key needs to be in the on position. Should measure about 13.5 volts DC.

If so, see test #8

If not, dc/dc converter is bad, replaced and retest

Test #5

Measure voltage between pin #4, 5 or 6 of DC/DC converter 12 pin connector (Connector must be plugged in for this test) and top of F1 fuse. Both sides of fuse should measure 13.5 volts DC.

If so, see test #6.

If only one side fuse is blown, try new good fuse and retest.

If neither side measure voltage, then you have a wiring/connection issue in the fuse panel or between fuse panel and DC/DC converter.

Test #6

Measure voltage between pin #4, 5 or 6 of DC/DC converter 12 pin connector (Connector must be plugged in for this test) or any small black wire at the 15-pin connector going to center console and pin #1 of

ignition switch. Should measure 13.5 volts DC.

If so, see test #7.

If not, you have a wiring issue between the ignition switch and F1 fuse panel.

Test #7

Measure voltage between pin #4, 5 or 6 of DC/DC converter 12 pin connector (Connector must be plugged in for this test) or any small black wire at the 15-pin connector going to center console and pin #2 of ignition switch with ignition switch in the on position. Should measure 13.5 volts DC.

If so, see test #8.

If not, you have a bad ignition switch.

Test #8

Measure voltage between pin #4, 5 or 6 of DC/DC converter 12 pin connector (Connector must be plugged in for this test) or any small black wire at the 15-pin connector going to center console and pin #86 of ignition switch relay with ignition switch in the on position. Should measure 13.5 volts DC.

If so, see test #9.

If not, you have a wiring issue between ignition switch and ignition switch relay.

Test #9

Measure voltage between B- of main battery pack and pin #30 of ignition switch relay Should measure pack voltage typically about 80 volts.

If so, see test #10.

If not since test #1 tested good, then you would have a wiring issue between the ignition relay and the wiring harness splice.

Test #10

Measure voltage between B- of main battery pack and pin #87 of ignition switch relay with ignition switch in the on position Should measure pack voltage typically about 80 volts.

If so, see test #11.

If not, ignition relay is bad and needs to be replaced.

Test #11

Measure voltage between B- of main battery pack or speed controller and pin #1 of speed controller with ignition switch in the on position Should measure pack voltage typically about 80 volts.

If so and controller is not powered (no LED lights) controller is bad and needs to be replaced. 

If not, you have a wiring issue between the ignition relay and speed controller.

Test #12

Measure voltage between B- of main battery pack and both sides of main 30-amp fuse located in the driver's side rear of vehicle. You should measure pack voltage typically 80VDC on both sides.
If have power on one side, then fuse is blown replace and retest. If no power, then you have a connection issue between 30A fuse and battery pack.