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1998-1999 Maintenance and Service Manual Supplement

1. Figure 15 2 Lift Vehicle with Floor Jack Figure 15 3 Support Vehicle with Jackstands MOTOR Read DANGER and WARNING on page 15 1 Motor Removal 1 Place Tow Run switch in TOW and disconnect battery cables negative cable first Figure 15 1 Page 15 2 2 Disconnect motor wires Use two wrenches to prevent post from turning Label wires to ensure proper recon nection See NOTE on page 15 2 3 Slightly loosen all the lug nuts on both rear wheels 4 Place floor jack under transaxle and raise rear of vehicle Figure 15 2 Page 15 3 then place jackstands under frame cross member between the spring mount and the side stringer just forward of each rear wheel Lower the vehicle to let the jackstands support the vehicle Figure 15 3 Page 15 3 See following WARNING A WARNING LIFT ONLY ONE END OF THE VEHICLE AT A TIME BEFORE LIFTING 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 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 15 3 MOTOR Motor Motor Removal Continued 5 Remove both rear wheels 6 Remove the nut cup washer and bushing from the bottom side of the shock
2. CHECK VOLTAGE AT A1 amp A2 MOTOR LOW VOLTAGE TERMINAL POSTS TEST PROCEDURE 5 REPLACE CONTROLLER REPLACE MOTOR Figure 11 11 Flow Chart 2 Vehicle Does Not Operate at Rated Top Speed Vehicle Operates Motor Braking Function Does Not CHECK MOTOR CNOVOLTAGE speep SENSOR CHECK WIRE PLUG TEST PROCEDURE 14 NO CONTINUITY 23 PIN CONNECTOR CONTINUITY VOLTAGE NOT TEST PROCEDURE 10 AS REQUIRED REPLACE MOTOR SPEED SENSOR REPLACE SPEED CONTROLLER REPAIR OR REPLACE Figure 11 12 Flow Chart 3 Vehicle Operates No Motor Braking 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 11 13 ELECTRICAL SYSTEM AND TESTING VEHICLE CHARGES Vehicle Operates Does Not Charge SEE SECTION 14 BATTERY CHARGER CHECK VEHICLE WITH A KNOWN WORKING CHARGER OR SEE SECTION 14 VEHICLE DOES NOT CHARGE NO RELAY CLICK NO TRANSFORMER VEHICLE DOES NOT CHARGE RELAY CLICKS TRANSFORMER HUMS CHECK ONBOARD COMPUTER BLACK WIRE CIRCUIT TEST PROCEDURE 11 INCORRECT READING REPLACE Test Procedures CHECK ALL WIRE NO CONTINUITY CONNECTIONS REPAIR OR REPLACE AS REQUIRED ONBOARD COMPUTER REPLACE FUSE Coe CHECK OBC GRAY WIRE CIRCUIT REPLA
3. Mibratiori Damage ee Ee aed Battery Charging eek General INFORMATION Y OCOO Charger Shuts Off After 16 Hours te enne nr nsn nns Deep Discharge qe EE Early Excessive Discharging cea aeaeceeeeanaeceecgaaaeeeeeeeegeaeeeceseaeeeeeesseeeeeeeeeeneaes Incoming AG Senvice Fleet Rotation Numbering Vehicles and Chargers Battery eere cette ete ane tna etna tees Battery Charger Test iode de dani Hed denied eee le e oae dederis On Charge Voltage Test itenim eo ie I e Hydrometer TeSt itcr ent too e e eee Bischargezbest ne tet tte m din Battery Troubleshooting Examples Battery Storage Charging Battery Pack With Low Voltage SECTION 14 POWERDRIVE BATTERY CHARGER General Informati n Later E RR CE Ua LR e e MD REL PowerDrive Charging Features e rect petu ne ix Fe ctae A bac ER ne e Lose dpa dte bd Battery Warning Light eere eret etie eee tede cere iene
4. ag deo ce The Gharge CIrclt eee D ee CL ESI OR he ts qu eee Tee de E Charger Installation and Use estne Checking Battery Condition After A Charge Cycle Start Charge Cycle Em Troubleshooting 2 Troubleshooting Guide Test Procedllles iP eta gaan cad ang sa aunties Sea abe General 2 ee e ete eu UO ERA basen ED Plug and Cord Replacement resani roliet ani a RRi A AA R AE ETA Charger Cord and Plug Page iv 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Charger 14 21 Heat Sink Assembly AL aie bn et enone neve 14 21 Urnesui PIE 14 22 Pc E c 14 22 Fuse LNK ep M 14 23 Voltage Suppressor E 14 23 Charger Relays aite ir tene ce eet esit doe eee 14 24 Charger AC Gircult Breaker auc cece iet nett edlen EE tee ed rire a ee Be 14 25 Charger AC Cord rive MR 14 25 SECTION 15 MOTOR General Information O E 15 1 Extemal Motor Te
5. 3 Install the adjustment screw 23 and nut 19 Figure 12 13 Page 12 17 NOTE WIPER ARM SHOULD BE ADJUSTED AFTER THE POTENTIOMETER IS FULLY ASSEMBLED 4 Slide the wiper arm assembly 20 into the potentiometer housing and install the bell crank 34 If ball stud 33 was removed insert it through the bell crank with ball stud facing down and away from housing and install the nut 35 While holding ball stud with a wrench tighten the nut to 5 ft lb 7 N m Figure 12 13 Page 12 17 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement 12 11 ELECTRICAL COMPONENTS Multi step Potentiometer Multi step Potentiometer Assembly Continued 5 While holding the bell crank so the arm does not exert a load on the housing install the nut 32 and tighten to 9 ft lb 12 N m Figure 12 13 Page 12 17 6 Install screw 29 lock washer 9 and nut 30 through potentiometer housing Figure 12 13 Page 12 17 7 Install nuts 30 and yellow 18 gauge wire 8 onto the screw and tighten to 40 in Ib 4 5 N m A WARNING e MAKE SURE WIPER ARM ROTATES FREELY IN POTENTIOMETER HOUSING IF ARM BINDS OR STICKS IT MUST BE REPLACED 8 Adjust the potentiometer arm See Page 12 13 Multi step Potentiometer Installation A CAUTION BEFORE INSTALLING THE WIPER SWITCH INSPECT THE HOUSING FOR CRACKS OR DAMAGE IF THE HOUSING IS DAMAGED THE ENTIRE HOUSING WITH FIXED CONTACTS MUST BE R
6. Page 14 4 1998 1999 PowerDrive Plus Maintenance and Service Supplement POWERDRIVE BATTERY CHARGER Charger Installation and Use A WARNING THE USE OF AN IMPROPER EXTENSION CORD COULD RESULT IN FIRE OR ELECTRIC SHOCK DO NOT OPERATE THIS CHARGER IF IT HAS RECEIVED A SHARP BLOW WAS DROPPED OR WAS OTHERWISE DAMAGED MAKE SURE IT IS OPERATING PROPERLY BEFORE PUTTING IT BACK IN USE DO NOT ALLOW CLOTHING BLANKETS OR OTHER MATERIALS TO COVER THE CHARGER e CHARGERS CAN IGNITE FLAMMABLE MATERIALS AND VAPORS DO NOT USE NEAR FUELS GRAIN DUST SOLVENTS THINNER OR OTHER FLAMMABLES KEEP CHARGER DRY DO NOT EXPOSE TO RAIN STORE INDOORS ONBOARD SOLID STATE COMPUTER SPEED CONTROLLER FUSE LINK No 10 BLACK No 6 BLACK 7 CHARGER No 10 BLACK fo RECEPTACLE Li No 10 BLACK No 18 GRAY SENSE LEAD FUSE No 10 RED BLACK TO FRONT NEGATIVE OF VEHICLE TERMINAL RED TO POSITIVE TERMINAL PLACE TOW RUN SWITCH IN THE TOW POSITION BEFORE DISCONNECTING BATTERY CABLES Figure 14 2 Charge Circuit Normal Charger Operation 1 With the charger DC output cord disconnected from the batteries connect the power supply cord to a 120 volt 60 hertz single phase outlet 2 Connect charger DC plug to charger receptacle located on the seat support panel Figure 14 3 Page 14 6 The charger will activate automatically within 2 to 15 seconds after the DC plug is connected 19
7. If the read ing is zero volts proceed to step 2 If the reading is 48 50 volts proceed to Test 3 See WARNING on page 11 11 2 If reading is not 48 50 volts place insulation probe on blue 18 gauge wire at a point between OBC six pin con nector and main wire harness If reading is zero volts check blue wire terminal connectors inside six pin connec tor at OBC six pin connector Make sure pins are properly aligned inside housing Make sure wire colors match Page 11 14 1998 1999 PowerDrive Plus Maintenance and Service Supplement ELECTRICAL SYSTEM AND TESTING Test Procedures 3 If reading is zero volts plug the charger DC cord into the vehicle charger receptacle If the dash light illumi nates for 10 seconds the OBC is now activated and the reading at the OBC blue wire should be approximately 48 50 volts When the DC cord is disconnected the solenoids should click on for two seconds and then click off If the vehicle now operates normally the DC cord has powered up the electrical system The electrical sys tem should also power up when the accelerator pedal is depressed To check the accelerator pedal function see Test Procedure 4 4 Ifthe dash light illuminates and the solenoids do not click 41 Using a multimeter set to 200 volts DC place black lead on battery number and place red lead with insulation probe on blue 18 gauge wire at OBC six pin connector 4 2 With Tow Run switch in the RUN position the voltage reading sh
8. MOUNTING TAB Figure 15 14 Brush Installation VIEWED FROM DRIVER INSTALL MOTOR ON TRANSAXLE ALIGN AND INSTALL MOUNTING BOLT Figure 15 16 Motor Installation Figure 15 17 Motor Mount 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 15 13 Motor Speed Sensor Motor Speed Sensor Removal D 2 3 4 Place Tow Run switch in the TOW position and disconnect battery cables Figure 15 1 Page 15 2 Disconnect the three pin connector 22 Figure 15 18 Page 15 14 Remove the three retaining screws 24 from the retaining plate 23 located on the motor end shield 10 Figure 15 18 Page 15 14 Remove motor speed sensor 21 from recessed area on motor Figure 15 18 Page 15 14 Motor Speed Sensor Installation 1 Position the motor speed sensor 21 in the recessed area on the motor Sensor should fit flush against the motor Figure 15 18 Page 15 14 Position retaining plate 23 over motor speed sensor and align the three retaining plate holes with motor end shield holes Install three retaining screws 24 Figure 15 18 Page 15 14 3 Reconnect the three pin connector 22 Figure 15 18 Page 15 14 Reconnect battery cables positive cable first and tighten to 110 in lb 12 4 N m Coat terminals with Batter Protector Spray Club Car Part No 1014305 to minimize corrosion Place Tow Run switch in the RUN position Figure 15 1 Page 15 2 Figure 15 18 Instal
9. The vehicle charge circuit consists of the charger receptacle fuse link onboard computer and the batteries The negative terminal of the receptacle is connected to the onboard computer The 10 gauge black wire from the onboard computer connects to the B terminal on the speed controller and the 6 gauge black wire also on the con troller B terminal goes through the onboard computer and connects to the negative post of battery No 6 The positive terminal of the charger receptacle is connected to the positive post of battery No 1 The gray wire sense lead from the charger receptacle is connected to the sense lead fuse which is connected to the gray wire from the onboard computer If the charger works with one vehicle but does not work with another then most likely the problem is in the vehicle charge circuit Check the connections between the 18 gauge gray wire from the charger receptacle the sense lead fuse and the 18 gauge gray wire from the onboard computer Also check connections of the fuse link assembly located on the charger receptacle Figure 14 2 Page 14 5 CHARGER INSTALLATION AND USE Read DANGER and WARNING on page14 1 A WARNING DO NOT BYPASS THE SENSE LEAD FUSE DISCONNECT BOTH THE AC AND DC PLUGS BEFORE WORKING ON THE CHARGER OR CHANGING THE CHARGER CORD TO CONNECT THE CHARGER PLUG TO THE VEHICLE RECEPTACLE GRASP THE PLUG AND PUSH IT STRAIGHT INTO THE RECEPTACLE DO NOT ROCK OR BEND THE PLUG WARN
10. if I Nd j i DNI L3 i Hd IN pi 8 Figure 12 13 Multi step Potentiometer 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 12 17 ELECTRICAL COMPONENTS Energy Displacement Module Testing the Battery Warning Light Continued 5 Install the wedgelock in the six pin connector housing and reconnect the six pin connector plug Place the Tow Run switch in the RUN position and the battery light should illuminate If the light does not illuminate replace the battery warning light assembly Battery Warning Light Removal 1 Place Tow Run switch in TOW and disconnect the battery wires as shown Figure 12 1 Page 12 2 2 Remove center dash See Remove Center Dash on Page 12 2 3 Disconnect the brown wire at the spade terminal and remove the orange white wire from the key switch Do not allow wires to touch 4 Depress the two retaining tabs and remove the light from the center dash Battery Warning Light Installation 1 Install in reverse order of removal Reconnect battery wires positive cable first and tighten to 110 in Ib 12 4 N m Place Tow Run switch in the RUN position ENERGY DISPLACEMENT MODULE Read DANGER and WARNING on page 12 1 Energy Displacement Module Removal 1 Place Tow Run switch in the TOW position and disconnect battery cables Figure 12 1 Page 12 2 2 Remove the two 1 4 in nuts lock washers flat washers and bolts that secure the coil to the
11. 6 Mount solenoid 12 onto component mounting plate with mounting bracket 10 Figure 12 4 Page 12 5 Tighten thread rolling screws 11 to 20 2 2 N m Figure 12 4 Page 12 5 Install washers 8 wires 2 4 and 13 and lock nuts 1 onto large mounting posts Tighten nuts to 60 in Ib 6 7 N m Figure 12 4 Page 12 5 See Section 11 Figure 11 1 Page 11 2 for wire destinations Install wires and 6 and nuts 7 onto small mounting posts Tighten to 18 in lb 2 0 N m Figure 12 4 Page 12 5 Install rear body access door Connect batteries positive cable first Figure 12 1 Page 12 2 and tighten to 110 12 4 N m Place Tow Run switch in RUN TYPICAL 2 PLACES Figure 12 5 Dynamic Braking Solenoid DYNAMIC BRAKING SOLENOID Read DANGER and WARNING on page 12 1 The dynamic braking solenoid is located on the driver side of the electrical component mounting plate Page 12 6 1998 1999 PowerDrive Plus Maintenance and Service Supplement ELECTRICAL COMPONENTS Onboard Computer OBC Testing the Dynamic Braking Solenoid See Test Procedure 8 Section 11 Page 11 17 Dynamic Braking Solenoid Removal 1 Place Tow Run switch in the TOW position disconnect the batteries and discharge the controller Figure 12 1 Page 12 2 Remove the rear body access door Disconnect all wires from the solenoid 12 Figure 12 5 Page 12 6 4 Loosen but do not remove one of the self ta
12. MULTI STEP TWO PIN O POTENTIOMETER CONNECTOR FORWARD REVERSE SWITCH FUSE AND RECEPTACLE ONBOARD e COMPUTER CONNECTOR Ent eg MOV1E SLIHM MOV1E MOTIAA PIN 4 WHITE WIRE PIN 5 BLUE WIRE PIN 3 GRN WHT WIRE PIN 6 YELLOW WIRE PIN 2 ORN WHT WIRE PIN 7 YEL BLK WIRE PIN 8 WHT BLK WIRE PIN 1 RED WIRE I 10 20 30 40 50 60 70 aO DYNAMIC BRAKING D 99 109 119 129 130 147 SOLENOID lt PIN 15 RED GRN WIRE 16 PIN 16 J PIN 9 PURPLE WIRE PIN 14 LT GRN WIRE PIN 10 ORANGE WIRE PIN 13 GREEN WIRE PIN 11 BLUE WHITE WIRE PIN 12 BROWN WIRE Figure 11 2 Wiring Diagram General Information 31IHW3SNVHO 2 o n SOLENOID 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 11 3 ELECTRICAL SYSTEM AND TESTING Electrical Circuits Zero Speed Detect This prevents the vehicle from rolling away uncontrolled should the driver park on slope and leave the vehicle without locking the park brake The vehicle will roll at about 1 mph If the zero speed detect function remains engaged for two seconds or more a warning buzzer will sound to alert the driver that motor braking has been activated A WARNING e ZERO SPEED DETECT MAY NOT HOLD THE V
13. Make sure all connections are tight Tighten to 110 in Ib 12 4 N m Coat all terminals with Battery Protec tor Spray CLUB CAR Part No 1014305 to minimize future corrosion 7 Give the batteries a full charge prior to operation This ensures all the batteries are fully charged and the cells are equalized prior to use 8 Place Tow Run switch in the RUN position BATTERY CARE Read DANGER and WARNING on page 13 1 PREVENTIVE MAINTENANCE To keep batteries in good operating condition follow these steps on a regular basis 1 Any corrosion build up on or around batteries should be removed immediately Terminal connections should be clean and tight Any frayed or worn wires should be replaced After all cables have been connected coat all terminals with Battery Protector Spray CLUB CAR Part No 1014305 to help prevent future corrosion 2 Batteries should be kept clean and dry to prevent self discharge Any dirt grime or acid spillage should be removed Wash batteries with a bristle brush using water and bicarbonate of soda baking soda 1 cup per gallon of water Rinse with water Do not allow solution to enter battery through the vent cap holes See Self Discharge below 3 Maintain proper electrolyte level See Battery Electrolyte Level Figure 13 6 Page 13 6 4 Batteries should be properly charged every day they are used Check the batteries periodically to see that they are in a full state of charge See Battery Charging Page 13
14. but inactive is the separator The separator does exactly what its name implies it separates the material of the positive and negative plates and prevents them from touching each other which would create elec trical shorts The separator is porous enough to allow charged ions to pass through between the positive and nega tive plates but not allow the two materials to contact each other Whenever two unlike metals are immersed in an acid solution an electric current is generated Page 13 2 1998 1999 PowerDrive Plus Maintenance and Service Supplement BATTERIES Common Misconceptions About Batteries INE In a deep cycle battery the negative plates contain lead Pb and the positive plates contain lead dioxide PbO These plates are immersed in a sulfuric acid solution H5SO4 Figure 13 1 Page 13 2 During discharge the chemical reaction inside the battery causes the sulfate 501 to break away from the Fig ure 13 2 Page 13 2 The sulfate SO4 combines with the lead Pb on both plates forming lead sulfate PbSO The oxygen from the positive plates combines with hydrogen from the electrolyte to form water H5O Figure 13 3 Page 13 2 The result is two similar metals lead sulfate PbSO immersed in water H20 This will not generate electricity since the battery is completely discharged When a discharged battery is connected to a charger the process is reversed The sulfate SO is forced from the plates
15. pin of the DC plug the positive pin and negative pin are identified on the plug If tester does not register continuity cord and plug must be replaced Place the continuity tester probe on the negative pin of the DC plug Tester should register no continuity If tester registers continuity cord and plug must be replaced Place the continuity tester probe on the unmarked middle pin of the DC plug Tester should register no con tinuity If tester registers continuity cord and plug must be replaced 9 Move the continuity tester clip to the black wire of the DC cord Figure 14 18 Page 14 20 Place the continuity tester probe on the negative pin of the DC plug Tester should register continuity If tester does not register continuity cord and plug must be replaced Page 14 18 1998 1999 PowerDrive Plus Maintenance and Service Supplement POWERDRIVE BATTERY CHARGER Test Procedures 11 Place the continuity tester probe on the unmarked middle pin of the DC plug Tester should register no con tinuity If tester registers continuity cord and plug must be replaced 12 Move continuity tester probe to the blue wire of the DC cord Figure 14 18 Page 14 20 Check for continuity at the middle pin Tester should register continuity If tester does not register continuity replace DC cord Transformer A WARNING e BEFORE PERFORMING THIS TEST BE SURE THE AC PLUG IS NOT CONNECTED TO AN AC OUTLET
16. 4 Record reading Then set multimeter to 20 volts DC and place the red 4 probe at the positive terminal and the black probe at the neg ative terminal of each battery Record the readings The on charge voltage for the set should read between 56 0 volts and 63 0 volts depending on the age and state of charge of the batteries being tested If individual batteries read between 9 8 and 10 5 volts the vehicle may not have been fully charged when the problem occurred Send the vehicle back out to see if the problem reoccurs If the problem per sists go to hydrometer test If any battery reads below 9 3 volts or differs by more than 0 7 volts from the other batteries replace the battery If readings are below 9 8 volts but within 0 7 volts of each other the batteries are old Old batteries may have enough capacity left to last several more months Go to hydrometer test See Troubleshooting Chart Figure 13 7 Page 13 9 and examples on following pages HYDROMETER TEST A hydrometer measures the specific gravity of the battery s electrolyte The higher the specific gravity the higher the state of charge of the batteries A fully charged battery should read between 1 250 and 1 280 at 80 F Never add acid to batteries to obtain a higher specific gravity Performing the Hydrometer Test 1 Be sure batteries have sufficient electrolyte to cover plates by approximately 1 2 in and are fully charged prior to beginning test If water must be added rech
17. 6 5 Keep hold downs tight See Vibration Damage Page 13 6 SELF DISCHARGE Dirty batteries can provide a path for a small current draw that can slowly discharge batteries thus wasting valuable energy To prevent self discharge batteries should always be kept clean Hot weather also has an effect on a battery s self discharge rate The higher the temperature the quicker a set of batteries will discharge In hotter climates therefore batteries should be checked more often When storing batter ies keep in a cool place See Battery Storage Page 13 14 ELECTROLYTE LEVEL A CAUTION DO NOT ALLOW BATTERY ACID FROM BATTERY CAPS OR HYDROMETER TO DRIP ONTO THE FRONT OR REAR BODY OF THE VEHICLE BATTERY ACID WILL CAUSE PERMANENT DAMAGE WASH IMMEDIATELY Add water only after charging unless the electrolyte is below the level of the plates If the electrolyte level is below the level of the plates add just enough water to cover the plates and then charge the batteries After charging fill with water to the level indicator Filling a battery to the level indicator before charging will result in overfilling because the electrolyte level will rise during charging and some of the electrolyte may bubble out of the cap This reduces the batteries capacity and corrodes the metal parts around the battery The electrolyte level should be checked weekly to be sure electrolyte is at its proper level Figure 13 6 Page 13 6 Never allow the
18. AC and DC cords See WARNING on page 14 21 Remove the charger cover Disconnect the two black wires attached to circuit breaker Figure 14 21 Page 14 24 WN With a pair of pliers squeeze in the retaining tabs the sides of the circuit breaker and remove the circuit breaker through its mounting hole in the face of the charger Figure 14 21 Page 14 24 AC Circuit Breaker Installation 1 Install in reverse order of removal CHARGER AC CORD AC Cord Removal Disconnect the and DC cords See WARNING page 14 20 Remove the charger cover Disconnect the AC cord black wire at the circuit breaker Figure 14 21 Page 14 24 Disconnect the AC cord white wire at the primary coil tan wire Figure 14 21 Page 14 24 Disconnect the AC cord green wire at the charger base Figure 14 21 Page 14 24 Use a pair of pliers to grip the strain relief bushing and remove it and the AC cord from the charger a Cord Installation 1 Insert the black white and green leads of the new AC cord into the charger through the hole the charger face Figure 14 21 Page 14 24 2 Connect the black wire to the circuit breaker the white wire to the primary coil and the green wire to the charger base Figure 14 21 Page 14 24 See following NOTE NOTE MAKE SURE THE GREEN GROUND WIRE IS TIGHTLY SECURED TO THE CHARGER BASE 3 Position the strain relief bushing on the AC cord 4 Using pli
19. AC power is supplied to the primary coil of the transformer When the relay closes an audible click can be heard and then as power is supplied the transformer should hum and the ammeter should indicate the charge rate Test Procedure 1 Battery Voltage Too Low or Faulty Connection Between Plug and Recep tacle 1 Check the DC plug and receptacle for damage dirt corrosion or any condition that might prevent a good electrical connection 2 Inspect the receptacle contacts to ensure that they are not damaged and they are firmly seated within the receptacle 3 Checkthe wire connections to the charger receptacle Page 14 12 1998 1999 PowerDrive Plus Maintenance and Service Supplement POWERDRIVE BATTERY CHARGER Test Procedures 3 1 Verify the 10 gauge red wire from the charger receptacle is connected to the positive post of battery No 1 Figure 14 10 Page 14 13 3 2 Make sure the two nuts that secure the two 10 gauge black wires to the receptacle fuse assembly are tight Figure 14 9 Page 14 13 3 3 Check the connections of the 18 gauge gray wire from the receptacle to the sense lead fuse and from the sense lead fuse to the onboard computer gray wire Figure 14 9 Page 14 13 A WARNING DO NOT BYPASS THE SENSE LEAD FUSE 3 4 Remove the gray sense lead fuse assembly and check its continuity with an multimeter set to 200 ohms 34 The resistance should be less than 2 ohms 4 With multimeter set to 200 vol
20. CORDSET HEAT SINK eC C FUSE ASS Y AMMETER 15 AMP AC CIRCUIT BREAKER SECONDARY COIL PRIMARY COIL TRANSFORMER CASE GROUND AC CORDSET Figure 14 4 PowerDrive Battery Charger Wiring Diagram 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement 14 7 POWERDRIVE BATTERY CHARGER Troubleshooting TAN WIRE TO PRIMARY COIL PRIMARY COIL SECONDARY COIL GREEN GROUND WIRE DC CORD BLACK WIRE TO P RED WIRE CIRCUIT BREAKER A BLACK WIRE TO 12 POWER RELAY m WIRE TO DC CORD 7a Ew RED WIRE j PRIMARY COIL TO RELAY 2759 SECONDARY COIL LEADS TAN SIUE WHE TO RELAY SECONDARY COIL DC CORD LEADS BLACK BLACK WIRE TO AMMETER RED WIRE TO HEAT SINK Figure 14 5 PowerDrive Battery Charger TROUBLESHOOTING Read DANGER and WARNING on page 14 1 Use the following information Pages 14 9 through 14 12 as guides for troubleshooting PowerDrive Plus vehicles The Troubleshooting Guide on pages 14 9 and 14 10 encompasses the entire vehicle electrical system The flow charts on pages 14 10 through 14 12 refers specifically to the onboard computer and battery charger Test proce dures specified in these charts can be found on the pages immediately following Page 14 8 1998 1999 PowerDrive Plus Maintenance and Service Supplement POWERDRIVE BATTERY CHARGER Troubleshooting TROUBLESHOOTING GUIDE POWERDRIVE BATTERY CHARG
21. Connect black clip to the sense lead pin short pin of the DC plug Multimeter should indicate no continu ity If continuity is registered indicating a closed circuit then voltage suppressor has failed and should be replaced See following NOTE Relay 1 Disconnect both AC and DC plugs and remove charger cover See preceding WARNING 2 Remove the black 3 and tan 4 wires from the contact terminals of the relay Figure 14 16 Page 14 17 Place continuity tester leads on contact terminals of the relay Tester should register no continuity If tester registers conti nuity the relay contacts are welded shut and the relay must be replaced 3 Place continuity leads on contact terminals of relay With batteries connected insert the DC plug into the receptacle Tester should register continuity If tester does not register continuity the relay must be replaced 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14 19 POWERDRIVE BATTERY CHARGER Plug and Cord Replacement NOTE FAILURE IN A CLOSED CONDITION CAN ALSO BE DETERMINED BY PLUGGING THE CHARGER INTO A VEHICLE THEN UNPLUGGING CHARGER AND VISUALLY INSPECTING THE SENSE LEAD FUSE AT THE GRAY WIRE IF FUSE 15 BLOWN THEN VOLTAGE SUPPRESSOR HAS FAILED CLOSED AND BOTH FUSE AND VOLTAGE SUPPRESSOR SHOULD BE REPLACED THE VOLTAGE SUPPRESSOR CANNOT BE TESTED FOR FAILURE IN AN OPEN CONDITION FAILURE IN AN OPEN CONDITION WILL HAVE NO AFFECT ON VEHICLE CHARGING OPERAT
22. DYNAMIC BRAKING SOLENOID Figure 11 7 Power Circuit 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 11 9 ELECTRICAL SYSTEM AND TESTING Electrical Circuits ELECTRIC MOTOR The electric motor is discussed in Section 15 Motor THE CHARGE CIRCUIT The charge circuit consists of the onboard computer battery charger DC charger plug charger receptacle recepta cle fuse link and the battery pack The charge circuit supplies current from the battery charger to the batteries when the DC cord is plugged into the vehicle s charger receptacle The batteries will be discussed in Section 13 Batter ies FUSE AND RECEPTACLE Y ZEN S NON Rp LE Ss 2 ONBOARD COMPUTER FRONT OF VEHICLE PLACE TOW SWITCH IN THE TOW POSITION BEFORE REMOVE NEGATIVE DISCONNECTING BATTERY CABLE FIRST CABLES Figure 11 9 PowerDrive Plus Battery Configuration Page 11 10 1998 1999 PowerDrive Plus Maintenance and Service Supplement ELECTRICAL SYSTEM AND TESTING Index of Test Procedures DANGER MOST OF THE FOLLOWING TEST PROCEDURES ARE PERFORMED WITH THE BATTERIES CONNECTED TO THE ELECTRICAL SYSTEM RAISE THE REAR END OF THE VEHICLE AND SUPPORT ON JACKSTANDS CHOCK FRONT TIRES WEAR SAFETY GLASSES WHEN PERFORMING CIRCUIT TESTS FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH A WARNING IF A TEST PROCEDURE REQUIRES THE BATT
23. Disconnect the brake cables 4 Figure 16 9 Page 16 8 5 Disconnect the shock absorbers from their lower mounts Figure 16 10 Page 16 8 6 Disconnect the four motor wires Use two wrenches to prevent the studs from turning 7 With a floor jack supporting the transaxle remove lower spring shackle nuts and bolts Position shackles so they are clear of springs Figure 16 11 Page 16 8 Figure 16 8 Support Vehicle on Jackstands A REMOVE BOLTS THEN ROTATE SHACKLES UP AND AWAY FROM SPRING DISCONNECT SHOCK ABSORBERS FROM LOWER MOUNTS Figure 16 10 Disconnect Shocks Figure 16 11 Shackles Page 16 8 1998 1999 PowerDrive Plus Maintenance and Service Supplement TRANSAXLE Transaxle Transaxle Removal Continued 8 Ifa chain hoist was used to raise the vehicle lift the vehicle high enough to permit easy access and clearance for removal of the motor If a floor jack was used to raise the vehicle lower the transaxle enough to permit easy access and clearance for removal of the motor 9 Remove three motor mounting bolts Figure 16 13 Page 16 8 and the motor positioning bolt Figure 16 21 Page 16 12 mounting the motor to the transaxle A WARNING e MOTOR WEIGHS APPROXIMATELY 42 LBS USE CARE WHEN SLIDING MOTOR OFF INPUT SHAFT IN STEP 9 FINGERS MAY GET PINCHED WHEN MOTOR DISENGAGES REST LEAF SPRINGS ON FLOOR MOTOR M
24. I 4 LOW VOLTAGE TEST PROCEDURE 6 COR REPAIR OR REPLACE TOW SWITCH NO CONTINUITY REPLACE OBC CIRCUIT AS REQUIRED VOLTAGE READINGS ARE ZERO REPLACE CONTROLLER NO VOLTAGE READING REPLACE TEST PROCEDURE 15 SOLENOID Gor CHECK MULTI STEP POTENTIOMETER TEST PROCEDURE 4 VOLTAGE READINGS ARE CORRECT VY CHECK VOLTAGE AT 1 AND A2 REPLACE CONTROLLER MOTOR TERMINAL POSTS TEST PROCEDURE 5 VOLTAGE READING CORRECT REPLACE LOW VOLTAGE READING MOTOR CHECK FOR SHORT CIRCUIT IN MOTOR SHORT CIRCUIT REPLACE MOTOR Figure 11 10 Flow Chart 1 Vehicle Does Not Operate 1998 1999 PowerDrive Plus Maintenance and Service Supplement ELECTRICAL SYSTEM AND TESTING Diagnostic Flow Charts Vehicle Does Not Operate At Rated Top Speed CHECK BATTERY PACK LOW VOLTAGE VOLTAGE UNDER HOT COIL LOAD RECHARGE TEST CHECK DYNAMIC TEST PROCEDURE 7 BATTERIES AS BRAKING SOLENOID REQUIRED TEST PROCEDURE 8 REPLACE CONTROLLER CHECK MULTI STEP POTENTIOMETER INCORRECT CHECK VOLTAGE VOLTAGE READINGS READINGS AT PIN 7 ARE CORRECT YELLOW WIRE ADJUST OR REPAIR TEST PROCEDURE 4 REPLACE DYNAMIC POTENTIOMETER BRAKING SOLENOID
25. NOT TOUCH THE ENERGY DISPLACEMENT MODULE RESISTOR COIL IT MAY BE EXTREMELY HOT A HOT ENERGY DISPLACEMENT MODULE COULD CAUSE SEVERE BURNS Test Procedure 8 Dynamic Braking Solenoid Activating Coil 1 With key switch ON and Forward Reverse switch in FORWARD place Tow Run switch in RUN Using a multimeter set to 200 volts DC place the red lead on battery No 1 positive post and the black lead on the brown wire at the dynamic braking solenoid small post With the accelerator pedal up the reading should be less than 1 volt With the accelerator pedal depressed the reading should be 48 50 volts full battery voltage See WARNING on page 11 11 2 If the reading is not approximately 48 volts when the accelerator pedal is depressed check the continuity of the brown wire and check pin 12 in the 23 pin connector see Test Procedure 10 If the connector and continuity readings are correct replace the controller If the reading is approximately 48 volts proceed to step 3 3 Using a multimeter set to 200 volts DC place black lead on battery No 6 negative post and place red lead on the orange white wire at dynamic braking solenoid small post The reading should be 48 to 50 volts full battery voltage with the accelerator pedal either up or fully depressed key switch OFF and the Forward Reverse rocker switch in NEU TRAL and Tow Run switch in RUN If reading is zero volts check continuity of the orange white wire to the blue OBC wire i
26. Removal Type K Transaxle Only 1 Remove the retaining ring 7 from the axle shaft Figure 16 4 Page 16 4 2 Place a bearing puller wedge attachment Club Car Part No 1012812 on the axle shaft between the wheel mounting flange and the bearing 3 Press bearing 5 and collar 4 off together Figure 16 6 Page 16 6 A CAUTION DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE AXLE SHAFT THIS COULD DAMAGE THE AXLE SHAFT WHEN PRESSING OFF THE BEARING AND COLLAR NOTE IT MAY BE NECESSARY TO HEAT THE COLLAR BEFORE THE COLLAR CAN BE REMOVED BEARING PULLER WEDGE ATTACHMENT PRESS RAM AXLE SEAL e AXLESEAL e gt Figure 16 6 Bearing and Collar Figure 16 7 Axle Seal Tool Page 16 6 1998 1999 PowerDrive Plus Maintenance and Service Supplement TRANSAXLE Axle Shaft and Bearing Axle Bearing Installation Type K Transaxle Only 1 If removed place retaining ring 6 on axle shaft 1 or 2 Figure 16 4 Page 16 4 The retaining ring will be loose on the axle shaft until it is installed into the axle tube 2 Apply two drops of Loctite 271 to the inside of the collar A CAUTION APPLY LOCTITE 271 TO INSIDE OF COLLAR ONLY NOT TO THE SHAFT SO THE LOCTITE WILL BE PUSHED AWAY FROM THE BEARING AS THE COLLAR AND BEARING ARE PRESSED ON IF LOCTITE GETS ON OR IN THE BEARING THE BEARING MUST BE REPLACED THE COLLAR SHOULD BE REMOVED MORE TH
27. Repair or replace as required 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 ELECTRICAL SYSTEM AND TESTING Test Procedures 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 Ifthe 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 correc
28. 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 ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL MECHANICAL AND ELECTRICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE TURN KEY SWITCH OFF PLACE FORWARD REVERSE ROCKER SWITCH IN THE NEUTRAL POSITION AND REMOVE KEY PRIOR TO SERVICING DO NOT WEAR LOOSE CLOTHING REMOVE JEWELRY SUCH AS RINGS WATCHES CHAINS ETC BEFORE SERVICING VEHICLE ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CONNECTIONS WHEN BATTERIES ARE CONNECTED USE EXTREME CAUTION TO AVOID SHORTING OF COMPONENTS OR WIRING TO AVOID UNINTENTIONALLY STARTING THE VEH
29. Tow Run switch in the TOW position Disconnect the batteries negative cable first as shown Figure 11 9 Page 11 10 Discharge the controller as instructed in the WARNING on page 11 11 Reconnect the batteries positive cable first and tighten terminals to 110 in Ib 12 4 N m Place Tow Run switch in the RUN position Test the drive vehicle If the problem has been fixed the vehicle will function normally If the problem still exists refer to the diagnostic flow charts beginning on page 11 11 E COMMUNICATION DISPLAY MODULE CDM CDM can be used to retrieve from the onboard computer four important items of information that can be useful in troubleshooting the PowerDrive Plus vehicle 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 func tion code is displayed in the window See Figure 11 14 Page 11 23 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 that the bat teries 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 F2 Energy units removed since last charge cycle If the display rea
30. WIPED CLEAN AND DRY BEFORE REASSEMBLY 1 If bearings 14 Figure 16 4 Page 16 4 or 13 Figure 16 5 Page 16 5 were removed during disassembly install new bearings using an arbor press 2 Assemble the differential gear case 21 Install the pin 31 Figures 16 4 or 16 5 Pages 16 4 or 16 5 Apply a small amount of oil to all thrust plates and to both ends of the pin Type K transaxles 22 While aligning the dowel pin assemble the two halves of the differential gear case 33 and 36 and rein stall the output gear 30 Figure 16 4 Page 16 4 2 3 Install eight hex bolts 28 and the bolt lock plates 29 Figure 16 4 Page 16 4 Tighten the bolts to 18 ft lb 24 N m 24 Bend the edges of the bolt locking tabs securely against the flats of the bolt heads to prevent the bolts from loosening and possibly causing damage Figure 16 17 Page 16 11 2 5 If the large gear 23 was removed from the intermediate gear insert key 22 into the keyway in the shaft and then press the large gear and the bearing 18 onto the shaft Be sure the key is properly posi tioned in the keyway before attempting to press on the large gear and bearing Figure 16 4 Page 16 4 Type G transaxles 2 6 Install four hex bolts 33 and output gear 32 Tighten bolts to 51 ft lb 69 N m Figure 16 5 Page 16 5 All Transaxles 3 Press a new bearing 20 Figure 16 4 Page 16 4 or 18 Figure 16 5 Page 16 5 onto the intermediate
31. and insert into the charger base 6 Position the charger cover on the base Install the attachment screws starting with the bottom holes Tighten the screws to 11 1 2 N m CHARGER REPAIRS Read DANGER and WARNING on page 14 1 A WARNING ALWAYS DISCONNECT THE ELECTRICAL CORDS BEFORE ATTEMPTING ANY TESTS OR REPAIRS TO THE CHARGER FIRST DISCONNECT THE AC CORD FROM THE AC OUTLET AND THEN DISCONNECT THE DC CORD FROM THE VEHICLE HEAT SINK ASSEMBLY Heat Sink Assembly Removal 1 Remove charger cover See preceding WARNING 2 Remove both secondary transformer leads tan from the heat sink assembly Figures 14 4 and 14 5 Pages 14 7 and 14 8 3 Remove the two red wires from the heat sink assembly Figures 14 4 and 14 5 Pages 14 7 and 14 8 4 Remove the nuts and bolts that secure the heat sink assembly to the case Heat Sink Assembly Installation 1 Place heat sink against charger base Make sure clear plastic insulator sheet is between the heat sink and the charger base Install the nuts and bolts that secure the heat sink assembly to the case Tighten the bolts to 22 in lb 2 4 N m Figures 14 4 and 14 5 Pages 14 7 and 14 8 2 Connect the red wire from the DC cord and the red wire from the charger relay to the center terminal post on the heat sink assembly Tighten nut to 18 in lb 2 0 N m Figures 14 4 and 14 5 Pages 14 7 and 14 8 3 Connect one of the secondary transformer leads tan to the
32. and then recon nect it The ammeter should jump to 14 to 18 amps and then taper to below 5 amps within 15 minutes If it does taper to below 5 amps within 15 minutes batteries are fully charged and the charger is functioning properly 2 If the charger does not taper to below 5 amps within 15 minutes batteries may not be receiving a full charge and the onboard computer should be checked See Test Procedure 2 NOTE OLD BATTERIES NEAR THE END OF USEFUL SERVICE MAY NOT TAPER TO BELOW 5 AMPS SEE SECTION 13 BATTERIES Test Procedure 8 Continuity AC Cord and Plug Check continuity of the AC cord Figure 14 17 Page 14 18 1 Disconnect the AC cord from its outlet and the DC plug from the receptacle then remove the charger cover 2 Disconnect black wire 1 of AC cord from charger AC circuit breaker 3 Figure 14 17 Page 14 18 3 Disconnect green wire 2 from charger case and position it so it does not touch any metal part of the charger Figure 14 17 Page 14 18 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14 17 POWERDRIVE BATTERY CHARGER Test Procedures Test Procedure 8 Continuity Continued 4 Using a multimeter set for 200 ohms place the red probe on the terminal at the end of the black wire 1 Fig ure 14 17 Page 14 18 Test for continuity on each of the flat blades and then on the ground pin of the AC plug Continuity should register on one flat blade only If any other
33. bottom terminal post of the heat sink assembly Tighten nut to 18 2 0 N m Figures 14 4 and 14 5 Pages 14 7 and 14 8 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14 21 POWERDRIVE BATTERY CHARGER Charger Repairs 4 5 Connect the other secondary transformer lead tan to the top terminal post of the heat sink assembly Tighten nut to 18 in Ib 2 0 N m Figures 14 4 and 14 5 Pages 14 7 and 14 8 Replace charger cover and check charger for proper operation TRANSFORMER Transformer Removal 1 2 Remove the charger cover See preceding WARNING Disconnect tan primary coil lead from the charger relay then disconnect the tan primary coil lead from the white wire in the AC cord Figures 14 4 and 14 5 Pages 14 7 and 14 8 Disconnect the two tan secondary transformer leads from the heat sink assembly Figures 14 4 and 14 5 Pages 14 7 and 14 8 Disconnect the two black secondary transformer leads from the fuse assembly Figures 14 4 and 14 5 Pages 14 7 and 14 8 Remove four bolts and nuts mounting transformer to case and remove transformer Figures 14 4 and 14 5 Pages 14 7 and 14 8 Transformer Installation 1 Install the transformer with the secondary coil to the rear of the charger case Tighten the four bolts and nuts to 28 in lb 3 2 N m Figures 14 4 and 14 5 Pages 14 7 and 14 8 2 Connect one secondary transformer lead tan to the top terminal post of the he
34. 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 Ifthe 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 52 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 mai
35. dash 3 1 Remove the plastic cap covering the screw on each side of the center dash panel Loosen but do not remove these screws 3 2 Insert screwdriver at the top center of the dash between dash and cowl brace Gently pry center dash out from under edge of cowl brace 3 3 Pull dash out approximately 1 in from the frame and then bend the top right corner of the dash inward while pulling the top of the panel out and down See following NOTE NOTE BENDING THE TOP RIGHT CORNER OF THE CENTER DASH INWARD DURING REMOVAL WILL PREVENT THE CONTACTS ON THE BACK OF THE KEY SWITCH FROM TOUCHING THE METAL FRAME AROUND THE DASH 3 4 Slide the dash panel up the steering column by snapping the top out and then rotating the panel out and up 3 5 Disconnect the orange and red wires from the buzzer Make sure the wire terminals on the key switch do not touch vehicle frame 4 Reconnect the battery wires positive cable first and tighten to 110 in Ib 12 4 N m Coat with Battery Protec tor Spray Club Car Part No 1014305 to minimize corrosion 5 Place the Forward Reverse rocker switch in REVERSE 6 Using a multimeter set to 200 volts DC place the black lead on battery No 6 negative post and place the red lead on the red wire terminal end that was disconnected from the reverse buzzer The reading should be approximately 48 volts full battery voltage 6 1 Ifthe voltage reading is correct proceed to step 7 6 2 If reading is
36. diodes must be replaced If a diode does not conduct current does not show continuity in either direction the entire heat sink assembly must be replaced 5 On rare occasions a single fuse link may melt due to excessive heat This can be caused by a loose internal fuse connection Check all three fuse connections inside the charger to be sure they are clean and tight The proper torque on the fuse link connections is 20 2 2 N m sure the charger is wired properly and all connections are clean tight See following WARNING A WARNING IF CONNECTIONS ARE NOT CLEAN AND TIGHT EXCESSIVE HEAT COULD RESULT WHICH MAY DAMAGE THE CHARGER Procedure 4B Both Diodes Fail To check the diodes use diode test procedure 4A If both diodes have failed closed both charger fuse links will be blown If both diodes have failed open the relay will close and the transformer will hum but the ammeter will not indicate any output If both diodes have failed open or closed the entire heat sink assembly must be replaced To determine why both diodes failed 1 Check the batteries and the receptacle to be sure they are wired in the correct polarity Also check the voltage and polarity at the receptacle 2 Make sure the charger DC plug is wired correctly the red wire should be connected to the center terminal of the heat sink assembly the blue wire should be connected to the relay coil and the black wire should be con
37. electrolyte level to fall below the tops of the plates because this will cause the exposed part of the plate to become permanently inactive For best results use a battery watering gun for adding water Check the elec trolyte level more frequently in hot weather or when batteries are old 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 13 5 BATTERIES Battery Charging LEVEL BATTERY INDICATOR CAP PLATES P ELECTROLYTE LEVEL AT LEAST 1 2 IN ABOVE PLATES OR TO LEVEL INDICATOR Figure 13 6 Battery Electrolyte Level MINERAL CONTENT For the longest battery life use distilled water in batteries However if tap water is going to be used be sure the mineral contents are below these levels ALLOWABLE CONTENT IMPURITY IN PARTS PER MILLION Suspended Matter Total Solids Calcium and Magnesium Oxides Iron Ammonia Organic Matter Nitrates Nitrites Chloride Contact your local water department for this analysis VIBRATION DAMAGE The battery hold downs should always be tight enough to keep the battery from bouncing Battery life may be severely shortened if the battery hold downs too loose Hold downs should be tightened to 40 4 5 N m Excessive vibration causes the plates to shed prematurely and sho
38. for ten AC power interrupted Test Procedure 3 Page 14 14 seconds at four second intervals with DC charger cord plugged in Onboard computer malfunction Test Procedure 2 Page 14 13 Charger failure See page 14 7 16 hour time out See page 14 3 Battery or batteries need to be replaced Section 13 Batteries Battery trouble light illuminates for ten Batteries are getting close to full discharge Recharge batteries seconds at four second intervals capacity golf round may be completed first with DC charger cord disconnected Onboard computer malfunction Test Procedure 2 Page 14 13 Battery or batteries need to be replaced Section 13 Batteries OBC CHARGER WILL NOT CHARGE BATTERIES CHECK POWER TO CHARGER OUTLET CONTINUED ON NEXT PAGE Figure 14 6 Flow Chart Page 14 10 1998 1999 PowerDrive Plus Maintenance and Service Supplement POWERDRIVE BATTERY CHARGER CHECK AC OUTLET FOR LOOSE OR FAULTY RECEPTACLE REPAIR AS REQUIRED CHARGE BATTERIES CHECK FOR TRIPPED OR FAULTY BREAKER CONTINUED FROM PAGE 14 10 DOES CHARGER AC OUTLET HAVE POWER DETERMINE CAUSE AND RESET BREAKER CHARGE BATTERIES ORIGINAL CHARGER IS MALFUNCTIONING CHECK CHARGER CIRCUIT BREAKER DETERMINE CAUSE AND RESET BREAKER CHARGE BATTERIES HAS BREAKER TRIPPED EXAMINE CHARGER DC F
39. inside axle tube Figure 16 4 or 16 5 Pages 16 4 or 16 5 NOTE TYPE TRANSAXLES IF RETAINING RING 6 MUST BE REPLACED THE ENTIRE AXLE SHAFT ASSEMBLY 1 OR 2 MUST BE REPLACED FIGURE 16 5 PAGE 16 5 5 Place a 1 4 in to 3 8 in to 10 mm diameter rod against the retaining ring and tap lightly at four to five loca tions around the retaining ring to ensure it is properly seated A WARNING BE SURE THE RETAINING RING IS PROPERLY SEATED IN ITS GROOVE IF THE RING IS NOT PROPERLY INSTALLED THE AXLE ASSEMBLY WILL SEPARATE FROM THE TRANSAXLE AND DAMAGE THE AXLE ASSEMBLY AND OTHER COMPONENTS LOSS OF VEHICLE CONTROL COULD RESULT CAUSING SEVERE PERSONAL INJURY 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement 16 7 TRANSAXLE Transaxle TRANSAXLE Read DANGER and WARNING on page 16 1 TRANSAXLE REMOVAL 1 Place chocks at the front wheels and slightly loosen lug nuts on both rear wheels 2 Place a floor jack under the transaxle and raise the rear of the vehicle Position jackstands under the frame cross member between the spring mount and the side stringer just forward of each rear wheel Lower the vehicle to let the jackstands support the vehicle Figure 16 8 Page 16 8 3 Remove rear wheels then thread one lug nut onto stud on each rear hub This will keep brake drums on hubs 4 Remove the cotter pins 1 brake cable clevis pins 2 and cable retaining E clips 3
40. new gasket Install the axle tube with five lock washers and bolts 9 and 8 Figure 16 4 Page 16 4 Tighten the bolts to 22 ft Ib 30 N m NOTE K TRANSAXLES IF THE DIFFERENTIAL CASE 33 AND 36 THE TRANSAXLE HOUSING 11 AND 24 OR AXLE TUBE 16 AND 40 FIGURE 16 4 PAGE 16 4 WAS REPLACED SEE SHIMMING THE TRANSAXLE ON PAGE 16 14 For G transaxles 8 5 Place 1 8 in bead of three bond liquid gasket on mating face of housing See following NOTE NOTE TRANSAXLES DO NOT USE A GASKET ON THE MATING FACE OF THE HOUSING USE AN 1 8 IN BEAD OF THREE BOND LIQUID GASKET INSTEAD 8 6 Install left half of transaxle housing 20 Figure 16 5 Page 16 5 8 7 Install eleven bolts in the case housing and tighten to 19 ft lb 25 7 N m Type G transaxles have no shims or gasket 8 8 Install axle tube with lock washers and bolts 9 and 8 Figure 16 5 Page 16 5 Tighten the bolts to 36 ft llb 49 N m For all transaxles 9 Install the brake assemblies as instructed in Section 6 Wheel Brake Assemblies 10 Apply a small amount of grease to the lip of the oil seal 17 Figure 16 4 Page 16 4 or 15 Figure 16 5 Page 16 5 11 Clean the splines on the axle shaft 1 and 2 Rotate the axle to align the shaft splines with the splined bore of the differential side gear Push the shaft in until the bearing seats against the shoulder in the axle tube Fig ures 16 4 and 16 5 Pa
41. operating conditions by continuously drawing amps from the batteries until voltage drops to 42 0 volts The discharge test is the hardest test on the batteries and the most time consuming to perform Use the battery dis charge tester CLUB CAR Part No 101831901 Performing the Discharge Test 1 Be sure the batteries are fully charged and that the electrolyte level is correct in all cells 2 Connect the tester leads to the positive post of battery No 1 and negative post of battery No 6 RED PROBE AT BATTERY NO 1 FRONT OF VEHICLE BLACK PROBE AT BATTERY NO 6 Figure 13 9 Discharge Test 3 Check and record the electrolyte temperature of the battery packs Check cell No 2 in each battery second cell from positive post 4 Reset discharge machine and turn the tester ON 5 When the batteries have been discharging for approximately 60 minutes set the discharge machine to function 3 and check battery set voltage Check voltage every 10 minutes throughout the rest of the test As soon as the battery 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 13 11 BATTERIES Battery Testing set voltage reaches 5 volts above the shut off point 42 0 volts use a multimeter to measure individual battery volt ages Measure and record the voltage of each battery to the nearest 01 volt NOTE THE TESTER WILL SHUT OFF AUTOMATICALLY WHEN SHUT OFF VOLTAGE IS REACHED Inte
42. reading is obtained the AC cord and plug must be replaced Put the red probe on the end of the green wire 2 and with the black probe check for continuity on both flat blades and on the ground pin of the AC plug Figure 14 17 Page 14 18 Tester should register continuity on only the ground pin If continuity registers on either of the flat blades or does not register on the ground pin the AC cord and plug must be replaced Disconnect the white wire 4 from the tan wire Figure 14 17 Page 14 18 Put red probe on the white wire and check for continuity on both flat blades and on the ground pin of the AC plug Figure 14 17 Page 14 18 Tester should register continuity on only one flat blade If any other reading is obtained the AC cord and plug must be replaced 200 SETTING Figure 14 17 AC Cord Plug and Continuity Test DC Cord and Plug 1 2 A Disconnect the AC cord from its outlet and the DC plug from the receptacle then remove the charger cover To check the continuity of the DC cord disconnect the black wire of the DC cord from the ammeter Figure 14 18 Page 14 20 Disconnect the red wire of the DC cord from the heat sink assembly Figure 14 18 Page 14 20 Disconnect the blue wire from the relay Figure 14 18 Page 14 20 Place the clip of the continuity tester on the red wire of the DC cord Figure 14 18 Page 14 20 Place the continuity tester probe on the positive
43. self tapping screws 3 that hold F amp R rocker switch case 2 to body Figure 12 3 Page 12 4 2 Remove red white 4 blue 5 and white 6 18 gauge wires from rocker switch Figure 12 3 Page 12 4 3 Depress locking tabs 1 on each end of switch and push switch out of case Figure 12 3 Page 12 4 Forward Reverse F amp R Rocker Switch Installation 1 Depress locking tabs 1 on each end of switch and push switch into case Figure 12 3 Page 12 4 2 Connect red white 4 blue 5 and white 6 18 gauge wires to rocker switch Figure 12 3 Page 12 4 3 Install the three self tapping screws 3 that hold the F amp R rocker switch case 2 to the body Figure 12 3 Page 12 4 Tighten to 20 in Ib 2 2 N m 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 12 3 ELECTRICAL COMPONENTS Accelerator Pedal Limit Switch TYPICAL 3 PLACES Figure 12 3 Forward Reverse Rocker Switch ACCELERATOR PEDAL LIMIT SWITCH Read DANGER and WARNING on page 12 1 Testing the Accelerator Pedal Limit Switch See Test Procedure 5 Section 11 Page 11 16 Accelerator Pedal Limit Switch Removal 1 anu FWD Place Tow Run switch in the TOW position disconnect batteries negative cable first Figure 12 1 Page 12 2 and discharge speed controller Remove the No 5 and No 6 batteries from the vehicle Remove the cover from the wiper switch housing Disconnect the accelerator rod from the ball stud on the wip
44. sys tem This prevents the possibility of driving the vehicle while the charger is plugged in and potentially dam aging the vehicle and charger Long Term Storage Charge PowerDrive Plus vehicles and PowerDrive Chargers are designed to be left connected with AC power to the charger during off season or long term storage The onboard computer will automatically activate the charger every 15 days To return the vehicle to service disconnect the DC cord from the vehicle wait 15 sec onds and then plug the DC cord back in The charger will activate Allow the vehicle to complete one full charge cycle before putting it into service Charger Disconnect The computer communication pin is shorter than the positive and negative pins in the charger DC plug In the event the charger plug is pulled from the receptacle while the charger is in operation the computer communication link will be disconnected first which will shut the charger off before the positive and negative pins disconnect This will help prevent possible damage to the plug and receptacle due to arcing 14 2 1998 1999 PowerDrive Plus Maintenance and Service Supplement POWERDRIVE BATTERY CHARGER The Charge Circuit BATTERY WARNING LIGHT The PowerDrive vehicle features a dash mounted warning light above steering column which when the vehicle is in operation indicates low battery voltage or when the vehicle is being charged indicates a charging problem The battery warning ligh
45. 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 Ifthe 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 Ifthe 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 11 19 ELECTRICAL SYSTEM AND TESTING Test Procedures to the three pin connector If the wire continuity is correct replace the
46. vehicle receptacle there is a 2 to 15 second delay before charging begins Figure 14 1 Page 14 2 The OBC records the amount of energy consumed as the vehicle is used then directs the charger to replace exactly the amount of energy needed to fully replenish the batteries The charger then shuts off automatically preventing the possibility of either undercharging or overcharging The computer accomplishes this by detecting when the exact amount of energy required has been returned to the batteries 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement 14 1 14 POWERDRIVE BATTERY CHARGER General Information NOTE SHORTLY AFTER CHARGING BEGINS THE CHARGER WILL SHUT OFF IN ORDER TO RUN A SELF DIAGNOSTIC PROGRAM AMMETER WILL DROP TO ZERO CHARGING WILL RESUME IN A FEW MOMENTS AMMETER RETURNS TO PREVIOUS RATE OF CHARGE THIS WILL BE REPEATED AT ONE HOUR AND AT TWO HOURS INTO THE CHARGE CYCLE Figure 14 1 PowerDrive Battery Charger POWERDRIVE CHARGING FEATURES Page Charge Interlock PowerDrive Battery Charger DC plugs have three pins rather than two blades that most standard charger plugs have Two of these pins are the positive and negative leads as on standard chargers the third pin is a sensing lead which is the communication link between the charger and the onboard computer When the charger plug is inserted into the vehicle receptacle the onboard computer locks out the vehicle s drive
47. when viewed from the front of the charger 2 Install the bus bar over the center branch of the fuse assembly and ammeter post Figure 14 20 Page 14 23 Tighten to 27 3 0 N m 3 Install a secondary transformer lead black to one of the two remaining terminals on the back of the fuse assembly Install the remaining secondary transformer lead black to the remaining terminal Figure 14 20 Page 14 23 Tighten to 27 in lb 3 0 N m 4 Replace charger cover VOLTAGE SUPPRESSOR The voltage suppressor protects the onboard computer by capturing very high but very brief voltage spikes which occur due to the collapse of the electrical field in the charger relay when the charger is disconnected from the vehi cle See also Test Procedure 8 Continuity Voltage Suppressor Page 14 19 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14 23 POWERDRIVE BATTERY CHARGER Charger Repairs Voltage Suppressor Removal 1 8 00 ON Disconnect the AC and DC cords See WARNING on page 14 21 Remove charger cover Remove nut attaching voltage suppressor 18 gauge red wire to heat sink Figure 14 21 Page 14 24 Disconnect blue wire to DC cord at quick disconnect terminal Figure 14 21 Page 14 24 Disconnect voltage suppressor from charger relay Figure 14 21 Page 14 24 Voltage Suppressor Installation 1 Install in reverse order of removal Tighten nut attaching voltage suppressor 18 gauge red
48. zero volts check red wire continuity and voltage output of OBC See Test Procedure 2 6 3 If the continuity readings are not correct repair or replace the red wire 6 4 If the continuity readings are correct proceed to step 7 7 Place the F amp R switch in REVERSE Using a multimeter set to 200 volts DC place the black lead on the orange wire terminal end that was disconnected from the reverse buzzer and place the red lead on battery No 1 positive post The reading should be approximately 48 volts full battery voltage 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 11 21 ELECTRICAL SYSTEM AND TESTING The Communication Display Module CDM Tes It is 7 1 If the voltage reading is correct in steps 7 replace the reverse buzzer 7 2 If reading is zero volts check orange wire continuity and connection at Pin 10 in 23 Pin connector 7 3 If there is no continuity in the orange wire or the Pin 10 terminal in the 23 Pin connector is not properly seated repair or replace as required 74 Ifthe orange wire continuity and 23 Pin connector are correct and there is no voltage at the orange wire replace the controller t Procedure 18 Rebooting Onboard Computer possible the Onboard Computer OBC can become locked causing the OBC solenoid lockout circuit to malfunction If this condition is suspected restart the computer as follows A Place the
49. 3 through the hole in the vehicle body and the receptacle backing plate Figure 12 8 Page 12 10 2 Insert receptacle into vehicle body 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 12 9 ELECTRICAL COMPONENTS Charger Receptacle Assembly Charger Receptacle Installation Continued 3 Install the four screws 1 that secure the receptacle assembly to the vehicle body and receptacle backing plate 8 Tighten screws to 11 in Ib 1 2 N m Figure 12 8 Page 12 10 4 Connect 18 gauge gray wire 9 to yellow fuse holder Make sure fuse 11 is installed in fuse holder 5 Connect the 10 gauge black wire 5 to the receptacle fuse link on the charger receptacle assembly Figure 12 8 Page 12 10 6 Connect the 10 gauge red wire 4 to the positive post of battery No 1 7 Connect battery cables positive cable first and tighten to 110 in lb 12 4 N m Figure 12 1 Page 12 2 Place Tow Run switch in RUN RECEPTACLE FUSE LINK The fuse link on the PowerDrive Plus vehicle should not blow under normal operating conditions However if the fuse link has blown the vehicle will not charge and the fuse must be replaced The fuse link is mounted on top of the charger receptacle in the battery compartment TYPICAL 2 PLACES Figure 12 8 Charger Receptacle Receptacle Fuse Link Removal 1 Remove the fuse link assembly 6 from the charger receptacle 7 by removing the two nuts and washers used to se
50. 8 and 15 12 Pages 15 7 and 15 11 Make sure the wedge attachment tool is supporting the inner race of the bearing If a press is not available secure a bearing puller Club Car Part No 1012811 to the bearing and pull the bearing off of the end of the armature shaft Support the shaft so it will not drop when the bearing is removed Figure 15 12 Page 15 11 Discard the bearing GUIDE RING INSPECTION NOTE FOR 1999 VEHICLES WITH SERIAL NUMBER 9912 752697 AND GREATER THE GUIDE RING 18 AND SNAP RING 20 HAVE BEEN ELIMINATED FIGURE 15 8 PAGE 15 7 1 Insert the alignment and installation tool Figure 15 11 Page 15 9 into the output end of the motor shaft and into the guide ring stopping the tool before it reaches the armature splines Turn the alignment tool in the shaft If guide ring moves and armature does not move the guide ring must be replaced Figure 15 11 Page 15 9 Page 15 8 1998 1999 PowerDrive Plus Maintenance and Service Supplement Reconditioning the Motor 2 To fabricate a guide ring installation tool glue a guide ring Club Car Part No 101789101 onto an input shaft Club Car Part No 1013764 and allow the glue to set Figure 15 11 Page 15 9 Guide Ring Removal 1 Using snap ring pliers remove the snap ring 20 Figure 15 8 Page 15 7 2 Insert fingers of a seal puller Club Car Part No 1012809 through guide ring 18 approximately 3 4 in 19 mm into the shaft Turn the adj
51. 98 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14 5 POWERDRIVE BATTERY CHARGER Charger Installation and Use Normal Charger Operation Continued 3 Monitor the ammeter for the correct charge rate The initial charge rate will vary from 15 to 19 amps depend ing upon the condition and depth of discharge of the batteries Slight variations in the initial charge rate may also result from AC line input voltages which are higher or lower than 120 volts Higher line voltages increase the initial charge rate while lower line voltages reduce the initial charge rate 4 Monitor the ammeter for about 30 seconds Under normal operating conditions when the charger is plugged into a vehicle with discharged batteries the ammeter will drop to zero for 2 to 3 seconds at the beginning of each charge cycle in order to perform a self diagnostic test This test will be repeated at one hour and two hours into the charge cycle See following NOTE NOTE IF THE BATTERIES ARE IN A FULLY CHARGED STATE AND THE VEHICLE HAS NOT BEEN DRIVEN THE ONBOARD COMPUTER WILL NOT PERFORM THE SELF DIAGNOSTIC TEST WHEN AIR TEMPERATURES FALL BELOW 65 F 18 3 C BATTERIES CHARGED IN UNHEATED AREAS SHOULD BE PLACED ON CHARGE AS SOON AS POSSIBLE AFTER USE COLD BATTERIES REQUIRE MORE TIME TO FULLY CHARGE Figure 14 3 Charger Receptacle Testing Charger Operation 1 With the DC plug disconnected from the vehicle charger receptac
52. A WARNING ALWAYS DISCONNECT THE ELECTRICAL CORDS BEFORE ATTEMPTING ANY REPAIRS TO THE CHARGER FIRST DISCONNECT THE AC CORD FROM THE OUTLET AND THEN DISCONNECT THE DC CORD FROM THE VEHICLE Test Procedure 4 Diodes Use test procedure 4A for single diode failures and testing of diodes If both diodes have failed use test procedure 4B Procedure 4A Single Diode Failure A single diode failure is indicated by one fuse link blowing closed circuit diode or by the charger output being low open circuit diode If a diode has failed the entire heat sink assembly must be replaced To check diodes 1 2 3 Disconnect the AC cord from its outlet and the DC plug from the receptacle then remove the charger cover Disconnect one transformer secondary coil lead from the diode terminal Figure 14 12 Page 14 15 Using a low voltage continuity tester or multimeter set to diode test function connect the red tester lead to the diode mounting plate and the black tester lead to a diode terminal and note the reading Figure 14 Page 14 14 1998 1999 PowerDrive Plus Maintenance and Service Supplement POWERDRIVE BATTERY CHARGER Test Procedures 12 Page 14 15 4 Reverse the tester leads and check each diode again and note the reading Figure 14 13 Page 14 15 A diode is designed to conduct current in one direction only if a diode conducts current shows continuity in both direc tions the complete heat sink assembly with
53. A WARNING e MAKE SURE WIRES ARE CONNECTED TO WIPER SWITCH CONTACTS EXACTLY AS STATED IF THEY ARE NOT THE VEHICLE COULD START IN A SPEED OTHER THAN FIRST 8 Install seven 1 4 20 hex nuts onto the threaded posts with resistors attached and tighten to 40 in Ib 4 5 N m Figure 12 12 Page 12 16 9 Coatall terminals with Battery Protector Spray Club Car Part Number 1014305 to minimize corrosion BATTERY WARNING LIGHT Read DANGER and WARNING on page 12 1 Testing the Battery Warning Light 1 Turn key switch OFF place Tow Run switch in TOW and place Forward Reverse rocker switch in NEUTRAL 2 Disconnect the six pin connector at the OBC 3 Remove the wedge lock from the six pin connector housing that is connected to the vehicle wire harness Remove the brown wire from the connector plug 4 Using a jumper wire with an alligator clip at each end connect one alligator clip to the negative post of bat tery No 1 and the other alligator clip to the brown wire terminal socket that was removed from the six pin connector plug Page 12 16 1998 1999 PowerDrive Plus Maintenance and Service Supplement ELECTRICAL COMPONENTS Battery Warning Light SJ SOR gt ALG 9 S3 o REFERENCE 7 ACCELERATOR ROD iss lw Am Sos D 2 n a o oJ M Me rera ams Y Y VON a HN if A INK Ay jN Jh i ENS j
54. AN TWO TIMES IF A BEARING IS REMOVED A THIRD TIME THE SHAFT AND COLLAR WILL NOT GIVE A PROPER FIT 3 Place the bearing and the collar on the shaft note this is a sealed bearing See following CAUTION A CAUTION IF THE BEARING WAS REMOVED FROM THE SHAFT REPLACE BEARING WITH NEW ONE 4 Place the bearing puller wedge attachment against the collar and press on both the bearing and collar See CAUTION on page 16 6 5 Install retaining ring 7 into the groove on the axle shaft Figure 16 4 Page 16 4 Axle Shaft and Oil Seal Installation 1 Clean bearing and seal seats in the axle tube 16 or 40 Figure 16 3 Page 16 3 or 14 or 35 Figure 16 5 Page 16 5 2 Place new seal 17 Figure 16 4 Page 16 4 or 15 Figure 16 5 Page 16 5 in axle tube with seal lip facing away from the bearing Use an axle seal tool Club Car Part No 1014162 and mallet to tap it in until it seats firmly in position Figure 16 7 Page 16 6 A hydraulic press may also be used with the axle seal tool 3 Clean the shaft splines and then insert the shaft splined end first through the seal and into the axle tube Be careful not to damage the seal Then advance the shaft through the inner bearing and rotate it to align the shaft splines with the splined bore of the differential side gear Continue advancing the shaft until the bearing seats against the axle tube shoulder 4 Using snap ring pliers install retaining ring 6
55. AND REPLACE BRUSHES ONE AT A TIME THIS METHOD ENSURES THE TERMINALS AND BRUSHES WILL BE PROPERLY POSITIONED IN THE RIGGING WHEN REPLACING BRUSHES REPLACE ALL FOUR BRUSHES NEVER REPLACE ONLY TWO INSTALL THE BRUSHES IN THE SAME RIGGING 180 APART FROM EACH OTHER 3 With brush rigging 12 facing down and held slightly above stator shell 2 insert the two terminal posts through insulators in stator shell wall at the A1 and A2 positions Insert brush holder screws 11 through the rubber sealed holes in the rigging and into the threaded holes in the mounting bracket Figure 15 8 Page 15 7 Tighten the screws to 20 in lb 2 2 N m See also Figure 15 14 Page 15 13 4 One at a time push brush spring extensions back from brushes and slide brushes back until they are com pletely retracted into their mounting slots Then position brush springs against sides of brushes so spring pressure will hold them in the retracted position Figure 15 6 Page 15 5 5 Slide the armature bearing end first into the stator shell Make sure the brushes are held back while positioning the armature for proper commutator brush contact Release the brushes and place the springs outside the brushes so the brushes are being held against the commutator See following CAUTION 6 Install end shield onto the stator shell Page 15 10 1998 1999 PowerDrive Plus Maintenance and Service Supplement MOTOR Motor Assembly SEAL PULLER CLUB CAR NO 1012809 WEDGE A
56. CE TEST PROCEDURE 12 ONBOARD COMPUTER CHECK RED WIRE TERMINAL SOCKET NO VOLTAGE IN RECEPTACLE TEST PROCEDURE 13 REPAIR OR REPLACE AS REQUIRED OK REPLACE ONBOARD COMPUTER Figure 11 13 Flow Chart 4 Vehicle Operates Does Not Charge TEST PROCEDURES Read DANGER and WARNING on page 11 11 Test Procedure 1 Battery Pack Voltage With batteries connected and using a multimeter set to 200 volts DC place the black lead on battery No 6 negative post and place the red lead on battery No 1 positive post Record the reading for reference this information will be referred to as full battery voltage and will be useful when performing other test procedures as well The voltage reading must be above 32 volts to activate the solenoid to operate the vehicle If the reading is below 32 volts test and recharge the batteries The battery charger will not turn on if the battery voltage is below 32 volts The charger relay will need to be by passed to activate the charger See WARNING on page 11 11 Test Procedure 2 Voltage Output From Onboard Computer 1 With batteries connected and using a multimeter set to 200 volts DC place black lead on battery No 6 nega tive post and red lead with insulation probe on blue onboard computer wire at a point between the OBC and the six pin connector The reading should be approximately 48 50 volts full battery voltage
57. COMMENDED LUBRICANT Brake pedal shaft bearings 1 Dry Moly Lube Club Car Part No 1012151 Brake Linkage and Pivots 2 Dry Moly Lube Club Car Part No 1012151 Semi Annually by Owner or Accelerator push rod pivots and mounts 3 Dry Moly Lube Club Car Part No 1012151 Trained Technician Every 50 hours of operation or every Forward Reverse Switch Contacts and 4 WD 40 100 rounds of golf charger receptacle Brake Slides 5 Dry Moly Lube Club Car Part No 1012151 Front Suspension 5 fittings 6 Chassis Lube EP NLGI Grade 2 Annually by Trained Check fill transaxle to plug level 7 e E OR dn 16 Technician Only Every 95 2i kr OF il or higher 100 hours of operation Inspect front wheel bearings 200 rounds of golf Repack as necessary 8 Chassis Lube EP NLGI Grade 2 See Figure 10 2 below Figure 10 2 Vehicle Lubrication Points VEHICLE CAPACITIES CAPACITIES Transaxle 22 oz 67 liters Tire Pressure 18 20 psi 124 138 kPa Page 10 4 1998 1999 PowerDrive Plus Maintenance and Service Supplement SECTION 11 ELECTRICAL SYSTEM AND TESTING THE BATTERY WIRES MUST REMAIN CONNECTED WHILE PERFORMING SOME TEST PROCEDURES RAISE THE REAR END OF THE VEHICLE AND SUPPORT ON JACKSTANDS REAR WHEELS SHOULD BE OFF THE GROUND WHILE PERFORMING ALL TEST PROCEDURES BATTERY EXPLOSIVE GASES DO NOT SMOKE KEEP
58. CUIT PROTECTION MAY RESULT IN A FIRE Each PowerDrive Plus electric vehicle is supplied with a fully automatic external battery charger as standard equipment To reduce the risk of electric shock the battery charger must be grounded The charger is equipped with an AC electric cord with an equipment grounding conductor and a grounding type plug It is for use on a nominal 120 volt 60 hertz single phased circuit The AC plug must be connected to an appropriate receptacle that is properly installed and grounded in accordance with the National Electric Code and all local codes and ordinances The use of an extension cord with the charger is not recommended If an extension cord must be used use a three conductor No 12 AWG cord with ground properly wired and in good electrical condition Keep it as short as possi ble no more than twelve feet Position all cords so they will not be stepped on tripped over or otherwise subject to damage or stress See following WARNING Provide adequate ventilation for the charger Keep all charger ventilation openings at least two inches away from walls and other objects See following WARNING A WARNING IMPROPER CONNECTION OF THE EQUIPMENT GROUNDING CONDUCTOR CAN RESULT IN AN ELECTRICAL SHOCK DO NOT USE AN ADAPTER TO PLUG CHARGER INTO A TWO BLADE OUTLET OR EXTENSION CORD EXTENSION CORD OR OUTLET MUST ACCEPT GROUNDED THREE BLADE PLUG WARNING CONTINUED ON FOLLOWING PAGE
59. ED WHEN DISCONNECTED SEE SECTION 11 FIGURE 11 1 WIRING DIAGRAM FOR PROPER CONNECTION 7 Insert bolts through the spring shackles and bushings in the leaf spring eyes Secure bolts with lock nuts Tighten to 15 ft lb 20 3 N m 8 Connect the brake cables 9 Install the shock absorbers Tighten shock absorber retaining nuts until the rubber bushings expand to the same size as the cup washers 10 Install the rear wheels Finger tighten lug nuts 11 Lift the vehicle and remove the jackstands 12 Lower vehicle and tighten the lug nuts using a criss cross pattern to 55 ft lb 74 6 N m 13 Test drive the vehicle to check for proper operation 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 16 15 NOTES NOTES am Ingersoll Rand Industrial Technologies pr Club Car Inc Web www clubcar com P O Box 204658 Phone 1 706 863 3000 Augusta GA 30917 4658 1 800 ClubCar USA Int l 1 706 863 3000 Fax 1 706 863 5808
60. EGATIVE 6 DISCONNECTING BATTERY CABLE FIRST CABLES Figure 15 1 PowerDrive Plus Battery Configuration EXTERNAL MOTOR TESTING Read DANGER and WARNING on page 15 1 Using a multimeter or continuity tester the following tests can be performed without disassembling the motor Test Procedure 1 Internal Short Circuit 1 Place Tow Run switch the TOW position and disconnect the batteries Figure 15 1 Page 15 2 2 Using two wrenches to prevent posts from turning disconnect wires from terminals on motor NOTE TAG THE MOTOR WIRES FOR IDENTIFICATION BEFORE DISCONNECTING 3 Using a multimeter set to 200 ohms 34 place black probe on motor housing Scratch through paint to ensure a good connection Place red probe A1 A2 F1 and F2 terminals respectively Figure 15 1 Page 15 2 Multimeter should indicate no continuity If readings are incorrect motor will need to be removed from the vehicle and repaired by a qualified technician See Motor Removal Page 15 3 3 1 Anincorrect reading from the A1 or A2 terminal indicates three possible problems a grounded A1 or A2 terminal a grounded wire in the brush area or a grounded armature commutator An incorrect reading for the F1 or F2 terminal indicates a possible grounded F1 or F2 terminal or field coil Figure 15 1 Test for Motor Short Circuit Page 15 2 1998 1999 PowerDrive Plus Maintenance and Service Supplement MOTOR Motor Test Procedure 2 Armat
61. EHICLE ON VERY STEEP GRADES DO NOT OPERATE VEHICLE ON SLOPES EXCEEDING 2096 GRADES Pedal Down Motor Braking This feature helps to control vehicle downhill speed When vehicle speed exceeds approximately 15 mph motor braking is activated which holds top speed to approximately 13 15 mph Motor brak ing is automatically disengaged when vehicle speed slows below approximately 13 mph Pedal Up Motor Braking When vehicle speed is above 12 mph releasing the accelerator pedal will activate motor braking which slows the vehicle to approximately 9 mph Once vehicle speed slows to below approxi mately 9 mph with the accelerator pedal still released motor braking will be deactivated and the vehicle will coast freely Motor Generator During motor braking the motor acts as a generator which creates electrical current The PowerDrive Plus electrical system has two current generating functions Regenerative Braking and Dynamic Braking Regenerative Braking When motor braking is activated the vehicle motor acts as a generator slowing the vehicle as it creates energy that is used to charge the batteries Dynamic Braking If the batteries are at or near full charge and do not require an additional charge the energy cre ated as the motor slows the vehicle is disposed of through the energy displacement module Tow Run Switch When the Tow Run switch is in the RUN position the vehicle will function normally When the switch is in the TOW position
62. EPLACED MULTI STEP TYPICAL 2 PLACES POTENTIOMETER MOUNTING Figure 12 9 Multi step Potentiometer Mounting 1 Position shim plate 8 on frame l Beam with mounting holes properly aligned Figure 12 9 Page 12 12 2 Push locking tabs out of retainers and remove potentiometer cover 9 Figure 12 9 Page 12 12 3 Position the potentiometer on the shim plate and frame with mounting holes aligned and insert the mount ing bolts 10 through the potentiometer base the shim plate and the frame as shown Figure 12 9 Page 12 12 4 Hold the mounting bolts in place while installing the washers 7 and nuts 6 Tighten nuts to 36 in lb 4 1 N m Figure 12 9 Page 12 12 Page 12 12 1998 1999 PowerDrive Plus Maintenance and Service Supplement ELECTRICAL COMPONENTS Multi step Potentiometer A WARNING AFTER INSTALLING THE WIPER SWITCH MAKE SURE IT IS SECURELY FASTENED TO THE VEHICLE FRAME 5 Connect the six pin connector to the wire harness at the multi step potentiometer 6 Connect the accelerator rod 1 to the potentiometer Figure 12 9 Page 12 12 7 Make sure wiper contact is positioned squarely on the last stationary contact when the accelerator pedal is depressed otherwise top vehicle speed will not be achieved 8 Make sure wiper switch and pedal group are properly adjusted See Section 5 Accelerator and Brake Pedal Group in the Maintenance and Service Manual 9 Install and c
63. ER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO 1 Relay does not close no transformer hum 1 Batteries disconnected Section 13 Batteries and ammeter does not move 2 Battery voltage is too low Test Procedure 1 Page 14 12 3 Poorconnection between plug Test Procedure 1 Page 14 12 and receptacle 4 DCplug and cord Test Procedures 1 and 5 Pages 14 12 amp 14 16 5 Onboard computer malfunction Test Procedure 2 Page 14 13 6 Gray sense lead fuse is blown Test Procedure 1 Page 14 12 7 Receptacle fuse link is blown Section 12 Electrical Components 2 Relay closes with an audible click 1 Improper AC outlet voltage Test Procedure 3 Page 14 14 transformer hum and ammeter does not move 2 Failed AC plug and cord Test Procedure 3 Page 14 14 3 Internal AC breaker Test Procedure 3 Page 14 14 4 Transformer primary coil Test Procedure 6 Page 14 16 5 Relay Test Procedure 8 Page 14 17 3 Relay closes and transformer hums but 1 Blown charger fuse Test Procedure 4 Page 14 14 ammeter does not move 2 Both diodes failed Test Procedure 4B Page 14 15 3 Onboard computer malfunction Test Procedure 2 Page 14 13 4 Failed transformer Test Procedure 6 Page 14 16 4 Relay operates intermittently 1 Blown fuse on red lead from OBC Section 11 Electrical System amp Testing 2 Defective charger relay Test Proce
64. ERIES TO BE DISCONNECTED PLACE THE RUN TOW SWITCH IN THE TOW POSITION FIRST THEN DISCONNECT THE BATTERIES BEFORE ANY TESTS OR REPAIRS ARE PERFORMED THE CAPACITORS INSIDE THE CONTROLLER MUST BE DISCHARGED THE CAPACITORS WILL NORMALLY SELF DISCHARGE AFTER THE BATTERY CABLES ARE DISCONNECTED HOWEVER TO ENSURE THE CAPACITORS ARE DISCHARGED PLACE THE FORWARD REVERSE ROCKER SWITCH IN REVERSE AND LISTEN FOR THE REVERSE BUZZER IF THE REVERSE BUZZER DOES NOT SOUND AFTER THE BATTERY CABLES ARE DISCONNECTED THE CAPACITORS ARE DISCHARGED IF THE REVERSE BUZZER SOUNDS TURN THE KEY SWITCH TO THE ON POSITION AND DEPRESS THE ACCELERATOR PEDAL UNTIL THE BUZZER CAN NO LONGER BE HEARD INDEX OF TEST PROCEDURES AU o Battery Pack Voltage Page 11 14 Voltage Output From OBC Page 11 14 Voltage At Main Solenoid Activating Coil Page 11 15 Multi step Potentiometer Voltage Page 11 15 A1 A2 Motor Voltage Page 11 16 Tow Run Switch Page 11 16 Battery Pack Voltage Under Load Page 11 17 Dynamic Braking Solenoid Activating Coil Page 11 17 Key Switch and Limit Switch Circuit Page 11 17 10 11 12 13 14 15 16 17 18 23 Pin Connector in the Controller Page 11 18 OBC SCR Circuit Page 11 18 OBC Gray Wire and Fuse Page 11 19 Voltage at Charger Receptacle Red Wire Page 11 19 Motor Speed Sensor Page 11 19 Main Solenoid Continuity Page 11 20 Forward Reverse Rocker
65. EVERE BURNS ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CONNECTIONS TO AVOID UNINTENTIONALLY STARTING THE VEHICLE PLACE THE TOW SWITCH IN THE TOW POSITION AND DISCONNECT BATTERIES AS SHOWN IN FIGURE 10 1 PAGE 10 2 THEN DISCHARGE THE CONTROLLER AS FOLLOWS PLACE THE FORWARD REVERSE ROCKER SWITCH IN THE REVERSE POSITION AND LISTEN FOR THE REVERSE BUZZER IF THE REVERSE BUZZER DOES NOT SOUND THE CAPACITORS ARE DISCHARGED IF THE REVERSE BUZZER SOUNDS TURN THE KEY SWITCH TO THE ON POSITION AND DEPRESS THE ACCELERATOR PEDAL UNTIL THE BUZZER CAN NO LONGER BE HEARD IMPROPER MAINTENANCE OR USE OF THE VEHICLE COULD RESULT IN DECREASED VEHICLE PERFORMANCE OR SEVERE PERSONAL INJURY LIFT ONLY ONE END OF THE VEHICLE AT A TIME BEFORE LIFTING 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 VEHICLE GENERAL INFORMATION To ensure continued reliable performance of the PowerDrive Plus vehicle a Preventive Maintenance program should be established and followed Preventive maintenance consists of the regular performance of scheduled vehicle service and maintenance procedures and is the only way to ensure the vehicle provides the safe reliable and
66. ICLE PLACE TOW RUN SWITCH IN TOW THEN DISCONNECT BATTERIES AS SHOWN IN FIGURE 11 9 PAGE 11 10 WHEN PERFORMING TESTS THAT DO NOT REQUIRE THE ELECTRICAL SYSTEM TO BE ENERGIZED GE The includes an onboard computer The electrical system in a PowerDrive Plus vehicle uses a shunt wound 3 2 hp motor and NERAL INFORMATION PowerDrive Plus vehicle uses a 48 volt electrical system that is powered by six eight volt lead acid batteries and includes several additional features Shunt Wound Motor Unlike a series wound motor which increases or decreases the current flow amperage through the armature and field coils at the same rate a shunt wound motor is able to vary the amount of amperage passing through the field coils separately from the current flow passing through the armature Motor Braking Under certain conditions a shunt wound motor also has the ability to act as an electrical brake to slow the vehicle There are three features of the PowerDrive Plus electrical system which will activate the motor braking function Zero Speed Detect Pedal Down Motor Braking and Pedal Up Motor Braking 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement 11 1 ELECTRICAL SYSTEM AND TESTING General Information Figure 11 1 Wiring Schematic Place Holder for Fold out Drawing Page 11 2 1998 1999 PowerDrive Plus Maintenance and Service Supplement ELECTRICAL SYSTEM AND TESTING TOW SWITCH 6
67. ING CONTINUED ON FOLLOWING PAGE 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement 14 3 POWERDRIVE BATTERY CHARGER Charger Installation and Use A WARNING TO DISCONNECT THE CHARGER FROM THE VEHICLE RECEPTACLE GRASP THE PLUG AND PULL IT STRAIGHT OUT OF THE RECEPTACLE DO NOT PULL ON THE CORD DO NOT TWIST ROCK OR BEND THE PLUG DO NOT CONNECT THE CHARGER TO BATTERY PACKS THAT ARE NOT COMPATIBLE WITH THE DC OUTPUT VOLTAGE SPECIFIED ON THE CHARGER OVERHEATING AND TRANSFORMER BURN OUT WILL RESULT DO NOT USE THE CHARGER IF THE PLUG CORD OR RECEPTACLE HAVE BEEN DAMAGED IN ANY WAY USE OF THE CHARGER WITH ANY OF THESE CONDITIONS COULD RESULT IN A FIRE PROPERTY DAMAGE PERSONAL INJURY OR DEATH DO NOT USE THE CHARGER IF THE DC PLUG DOES NOT MAKE A GOOD CONNECTION THE PLUG AND RECEPTACLE FEEL HOTTER THAN NORMAL THE PLUG PINS OR RECEPTACLE CONTACTS ARE BENT OR CORRODED THE PLUG RECEPTACLE OR CORDS ARE CUT WORN OR HAVE ANY EXPOSED WIRES THE PLUG CORDS CHARGER OR RECEPTACLE ARE DAMAGED USING THIS CHARGER WITH ANY OF THE ABOVE CONDITIONS COULD RESULT IN FIRE PERSONAL INJURY OR PROPERTY DAMAGE REPAIR OR REPLACE WORN OR DAMAGED PARTS BEFORE USING THE CHARGER EACH CHARGER SHOULD HAVE ITS OWN 15 OR 20 AMPERE BRANCH CIRCUIT PROTECTION CIRCUIT BREAKER OR FUSE IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE ANSI NFPA 70 AND LOCAL CODES AND ORDINANCES IMPROPER AC SUPPLY CIR
68. INTENDED USE OVERLOADING ABUSE OR NEGLECT INCLUDING FAILURE TO PROVIDE REASONABLE OR NECESSARY MAINTENANCE AS INSTRUCTED IN THE VEHICLE OWNER S MANUAL ACCIDENT OR ALTERATION INCLUDING INCREASING VEHICLE SPEED BEYOND FACTORY SPECIFICATIONS OR MODIFICATIONS WHICH AFFECT THE STABILITY OF THE VEHICLE OR THE OPERATION THEREOF WILL VOID THE WARRANTY CLUB CAR INC RESERVES THE RIGHT TO CHANGE SPECIFICATIONS AND DESIGNS AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION OR LIABILITY WHATSOEVER THERE ARE NO WARRANTIES EXPRESSED OR IMPLIED IN THIS MANUAL SEE THE LIMITED WARRANTY FOUND IN THE VEHICLE OWNER S MANUAL OR WRITE TO CLUB CAR INC Page ii 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement SECTION 10 PERIODIC MAINTENANCE General Information be Fe dee adde in beaded a Led utut re e 10 1 Daily Pre Operation Safety Checklist 10 2 Periodic Service Schedule 10 3 1 10 4 Vehicle lie 10 4 SECTION 11 ELECTRICAL SYSTEM AND TESTING General Information nn o t tete oboe estet at ei texte ud erede e dcs 11 1 Electrical tette eo i e este dett mem Rte 11 4 THe C
69. ION DUE TO THE EXISTENCE OF A SIMILAR COMPONENT LOCATED IN THE ONBOARD COMPUTER Ammeter Check continuity of the ammeter 1 Disconnect both AC and DC plugs and remove charger cover See preceding WARNING 2 Disconnect the black wire from the left ammeter post as viewed from inside the charger 3 Place the continuity tester clip on one of the ammeter posts 4 Place the continuity tester probe on the other ammeter post The tester should register continuity If the tester does not register continuity replace ammeter PLUG AND CORD REPLACEMENT Read DANGER and WARNING on page 14 1 The charger cord plug and receptacle are wear items and should be inspected daily Visually inspect them for cracks loose connections and frayed wiring they must be replaced when worn or damaged If charger plug and receptacle show signs of corrosion or become difficult to insert and remove the receptacle contacts and plug blades may be cleaned with a good electrical contact cleaner or lightly sprayed with WD 40 brand spray lubricant See Section 12 Page 14 9 for charger receptacle replacement DC CORD BLUE WIRE DE CORD TO RELAY BLACK WIRE TOAMMETER DC CORD Es STRAIN RELIEF BUSHING Figure 14 18 DC Cord Figure 14 19 Charger Cord Installation CHARGER CORD AND PLUG REPLACEMENT Charger Cord and Plug Removal 1 Disconnect the AC and DC plugs See preceding WARNING 2 Remove the charger cover 3
70. If 3096 contact is not shown surface contact should be adjusted 3 To adjust surface contact remove the spring cotter pin if present 18 and turn the adjustment screw 23 Figure 12 13 Page 12 17 until the surfaces of the multi step potentiometer arm brush and fixed contacts are parallel Figure 12 10 Page 12 14 See following NOTE NOTE A MID MODEL YEAR DESIGN CHANGE RESULTED IN THE REMOVAL OF THE SPRING COTTER PIN 18 AND THE REPLACEMENT OF THE HEX NUT 19 WITH A NYLON LOCK NUT FIGURE 12 13 PAGE 12 17 USE OF A LOCKING COMPOUND IS NOT NECESSARY IN CONJUNCTION WITH A NYLON LOCK NUT IF THE MULTI STEP POTENTIOMETER ARM BRUSH IS WORN TO OR BEYOND THE WEAR LIMIT LINE FIGURE 12 11 PAGE 12 14 IT SHOULD BE REPLACED IF ANY OF THE FIXED CONTACTS ARE EXCESSIVELY WORN PITTED OR BURNED THE ENTIRE HOUSING WITH FIXED CONTACTS MUST BE REPLACED A THREAD LOCKING COMPOUND HAS BEEN PLACED ON THE THREADS OF THE CONTACT STUDS TO PREVENT REMOVAL OF THE FIXED CONTACTS 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement 12 13 ELECTRICAL COMPONENTS Multi step Potentiometer Multi step Potentiometer Arm Adjustment Continued 4 After adjustment has been made apply drop of Loctite 290 thread locking compound to the adjustment screw 23 at the hex nut 19 Then install the spring cotter pin 18 through the hole in the adjustment screw Figure 12 13 Page 12 17 See preceding N
71. MPONENTS Key Switch PLACE TOW SWITCH IN THE TOW POSITION BEFORE REMOVE NEGATIVE DISCONNECTING BATTERY CABLE FIRST CABLES Figure 12 1 PowerDrive Plus Battery Configuration KEY SWITCH Read DANGER and WARNING above The key switch is mounted next to the steering column on the center dash panel Testing The Key Switch See Test Procedure 9 Section 11 Page 11 17 Key Switch Removal 1 Place Tow Run switch in the TOW position and disconnect batteries Figure 12 1 Page 12 2 See DANGER and WARNING on page 12 1 2 Discharge the speed controller See instructions in WARNING on Page 12 1 3 Remove center dash 3 1 Remove the plastic cap covering the screw on each side of the center dash 3 2 Loosen but do not remove the screw on each side of the center dash panel 3 3 Insert screwdriver at top center of center dash between dash and cowl brace Gently pry center dash out from under edge of cowl brace 3 4 Pull center dash out approximately one inch from the frame and then bend the top right corner of the center dash panel inward while pulling the top of the panel out and down See following NOTE NOTE BENDING THE TOP RIGHT CORNER OF THE CENTER DASH INWARD DURING REMOVAL WILL PREVENT THE TERMINALS 7 ON THE BACK OF THE KEY SWITCH FROM TOUCHING THE METAL FRAME AROUND THE DASH FIGURE 12 2 PAGE 12 3 4 Slide center dash panel up steering column by snapping top out and then rotating the panel out and up 5 Dis
72. Minutes 89 99 66 Minutes 50 Minutes 100 109 68 Minutes 54 Minutes 110 119 70 Minutes 57 Minutes 120 129 72 Minutes 60 Minutes 130 150 74 Minutes 62 Minutes Page 13 12 1998 1999 PowerDrive Plus Maintenance and Service Supplement BATTERIES Battery Testing BATTERY TROUBLESHOOTING EXAMPLES The following information represents a few examples of troubleshooting battery problems Example 1 Vehicle No 68 was suspected of having a defective battery due to its performance As a result the battery charger test was performed After a full charge the battery charger ammeter read 8 0 amps Next the on charge voltage test was performed and the following results were recorded BATTERY NO 1 2 3 4 5 6 ON CHARGE VOLTAGE 10 15 10 60 9 80 10 16 10 56 10 61 Battery No 3 appears to be suspect Battery Nos 1 and 4 are also suspect Next a hydrometer test should be con ducted on all batteries Hydrometer test results BATTERY NO 1 2 3 4 5 6 SPECIFIC GRAVITY CELL 1 POSITIVE POST 1 200 1 265 1 300 1 250 1 280 1 260 CELL 2 1 285 1 275 1 290 1 270 1 295 1 265 CELL 3 1 265 1 270 1 275 1 265 1 280 1 275 CELL 4 NEGATIVE POST 1 275 1 270 1 285 1 265 1 275 1 275 After the hydrometer test it appears that battery No 1 is the problem Next the discharge test was performed Discharge test results After a discharge
73. NE CONTINUED COLUMN TWO CONTINUED FROM PREVIOUS PAGE FROM PREVIOUS PAGE l DOES is CHARGER DETERMINE CAUSE REPLACE RELAY ACTIVATE FUSE BLOWN AND REPLACE FUSE NO CHARGE BATTERIES CHECK DIODES AS CHECK BATTERY DESCRIBED IN VOLTAGE TEST PROCEDURE 4 PAGE 14 14 CHARGE BATTERIES 15 eee saa VOLTAGE 32V INSPECT CHARGER REPLACE DIODE NO OR HIGHER RECEPTACLE FUSE HEAT SINK ASSEMBLY DIODES YES BY PASS CHARGER RELAY AS DESCRIBED IN i CHARGE BATTERIES CHECK AMMETER TEST PROCEDURE 6 5 DETERMINE CAUSE PAGE 14 16 FUSE BLOWN AND REPLACE FUSE o NO CHARGE BATTERIES FOR NO REPLACE AMMETER APPROXIMATELY TWO HOURS RECONNECT RELAY IN PROPER REPLACE CHARGE BATTERIES CONFIGURATION ONBOARD COMPUTER YES UII OLD 1 CHARGE BATTERIES SEE ME on CHARGE BATTERIES CHARGE BATTERIES Figure 14 8 Flow Chart Continued TEST PROCEDURES Read DANGER and WARNING on page 14 1 GENERAL The charger uses DC battery voltage through the onboard computer to close the charger relay which activates the charger AC circuit When the charger is operating properly there is a 2 to 15 second delay after the DC cord is plugged into the vehicle before the relay closes This delay allows time for the DC plug to make a secure connection with the receptacle before the AC circuit is activated and
74. ONS LIFT ONLY ONE END OF THE VEHICLE AT A TIME BEFORE LIFTING 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 TO AVOID UNINTENTIONALLY STARTING VEHICLE PLACE TWO SWITCH IN TOW THEN DISCONNECT BATTERIES AS SHOWN IN SECTION 11 FIGURE 11 9 PAGE 11 10 AND DISCHARGE THE CONTROLLER AS FOLLOWS TURN KEY SWITCH ON PLACE FORWARD REVERSE ROCKER SWITCH IN REVERSE 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 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 16 1 TRANSAXLE General Information GENERAL INFORMATION There are two types of transaxles used in the manufacture of the electric vehicle The different transaxles are identi fied by the orientation of the gear case bolts The Type G transaxle has gear case bolt heads toward the passenger side of the vehicle The Type K transaxle has gear case bolt heads toward the driver side of the vehicle Please note the parts used in these transaxles are not interchangeable with one another Service and repair procedures specific to each transaxle are n
75. OTE MULTI STEP POTENTIOMETER ARM BRUSH REPLACEMENT BR U N gt Place Tow Run switch in the TOW position and disconnect battery cables negative cable first Remove battery Nos 5 and 6 from the vehicle Figure 12 1 Page 12 2 Disconnect accelerator rod from ball stud and place the wiper switch arm on the topmost fixed contact Remove the first nut 30 and lock washer 9 from the bolt 29 and remove the 18 gauge yellow wire 8 Fig ure 12 13 Page 12 17 WIPER ARM BRUSH WIPER ARM BRUSH AND FIXED CONTACT Pe ae WEAR LIMIT LINE SHOULD SEAT FIRMLY AGAINST EACH OTHER WIPER ARM FIXED BRUSH CONTACT SIDE VIEW WIPER ARM BRUSH Ga Figure 12 10 Wiper Arm Brush and Fixed Contacts Figure 12 11 Wiper Arm Brush Wear Limit Line Remove the second and third nuts 30 from the bolt 29 and then remove the bolt from the potentiometer housing 1 Figure 12 13 Page 12 17 Remove the fourth nut 30 and wire 42 from the bolt 29 Figure 12 13 Page 12 17 7 Replace the wiper arm brush 27 as follows Figure 12 13 Page 12 17 11 12 13 7 1 Remove screw 25 and lock washer 14 Pull arm assembly away from fixed contacts Figure 12 13 Page 12 17 7 2 Remove the brush by pulling the wire through the hole in the wiper arm 7 3 Install new wiper arm brush assembly 27 Figure 12 13 Page 12 17 74 Instal
76. OUNTING THEN REMOVE U BOLTS INPUT PINION GEAR INTERMEDIATE DIFFERENTIAL GEAR ASSEMBLY GEAR CASE Figure 16 13 Motor Mounting Bolts INSTALL MOTOR ON TRANSAXLE ALIGN AND INSTALL POSITIONING BOLT Figure 16 14 Motor Positioning Bolt 10 Carefully remove the motor from the transaxle Slide the motor away from the transaxle until the motor spline becomes disengaged from the input shaft then lift motor out See preceding WARNING 11 Ifafloorjack was used pull floorjack from beneath the transaxle and allow the springs to rest on the floor 12 Remove the U bolts attaching the transaxle to the leaf springs Figure 16 12 Page 16 9 13 Carefully lift each end of the transaxle off its positioning pin on the leaf spring and slide the transaxle to the rear and out of the vehicle 14 If removal of the brake assemblies is required see Section 6 Wheel Brake Assemblies in the 1998 1999 DS Vehicle Maintenance and Service Manual 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 16 9 TRANSAXLE Transaxle Disassembly Inspection and Assembly TRANSAXLE DISASSEMBLY INSPECTION AND ASSEMBLY Read DANGER and WARNING on page 16 1 TRANSAXLE DISASSEMBLY AND INSPECTION 1 To detach axle tubes 16 and 40 Figure 16 4 Page 16 4 or 14 and 35 Figure 16 5 Page 16 5 from tran saxle housing remove bolts and lock washers 8 and 9 Figure 16 4 or 16 5 See following NOTE NOTE TYPE K TRAN
77. Remove the black lead of the charger DC cord 4 from the ammeter by loosening the nut 1 Support the ter minal as the nut is loosened to prevent rotation of the connection Figure 14 19 Page 14 20 4 Remove nut attaching red lead of charger DC cord onto the heat sink assembly Figure 14 18 Page 14 20 Page 14 20 1998 1999 PowerDrive Plus Maintenance and Service Supplement POWERDRIVE BATTERY CHARGER Charger Repairs 5 Remove the terminal on the blue charger DC cord lead at the relay Figure 14 18 Page 14 20 6 Using pliers squeeze the strain relief bushing and remove the cord set Figure 14 18 Page 14 20 Charger Cord and Plug Installation 1 Insert the leads of the new cord through the hole in the charger base 2 Attach the red lead of the new cord set to the center terminal of the heat sink and tighten the nut to 14 1 6 N m Figure 14 18 Page 14 20 3 Attach the blue lead of new cord set to the charger relay coil terminal Figure 14 18 Page 14 20 4 Attach the black lead of the new cord to the ammeter Install nut 1 onto post of ammeter slightly more than finger tight While holding the outside nut 1 turn the inside nut 2 counterclockwise 1 4 turn Figure 14 19 Page 14 20 See following CAUTION A CAUTION DO NOT ALLOW AMMETER POST TO ROTATE AS THE NUT IS TIGHTENED IF IT IS ALLOWED TO ROTATE THE AMMETER COULD BE DAMAGED 5 Using pliers put the strain relief bushing on the cord
78. S OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL ALWAYS WEAR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE WEAR A FULL FACE SHIELD AND RUBBER GLOVES WHEN WORKING WITH BATTERIES TURN KEY SWITCH OFF PLACE FORWARD REVERSE ROCKER SWITCH IN NEUTRAL AND REMOVE KEY PRIOR TO SERVICING DO NOT WEAR LOOSE CLOTHING REMOVE JEWELRY SUCH AS RINGS WATCHES CHAINS ETC BEFORE SERVICING VEHICLE ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CONNECTIONS BEFORE PERFORMING TESTS OR REPAIRS AND TO AVOID UNINTENTIONALLY STARTING THE VEHICLE MAKE SURE CAPACITORS ARE DISCHARGED PLACE TOW SWITCH IN TOW DISCONNECT BATTERY WIRES AS SHOWN IN FIGURE 14 3 PAGE 14 6 PLACE FORWARD REVERSE ROCKER SWITCH IN REVERSE AND LISTEN FOR THE REVERSE BUZZER IF THE BUZZER DOES NOT SOUND THE CAPACITORS ARE DISCHARGED IF THE REVERSE BUZZER SOUNDS TURN THE KEY SWITCH ON AND DEPRESS THE ACCELERATOR PEDAL UNTIL THE BUZZER CAN NO LONGER BE HEARD GENERAL INFORMATION The PowerDrive Battery Charger is an integral part of the PowerDrive Plus electrical system and one is included with every PowerDrive Plus vehicle Because it is controlled by the PowerDrive onboard computer OBC it can be used with Power Drive Plus or PowerDrive System 48 vehicles only The charger is automatic and has no external controls when it is plugged into the
79. SAXLES ONLY SHIMS ARE LOCATED BETWEEN THE DRIVER SIDE AXLE TUBE AND DIFFERENTIAL CASE BEARING DO NOT DAMAGE SHIMS IF SHIMS ARE REMOVED SET THEM ASIDE FOR REINSTALLATION 2 Remove 10 bolts 26 Figure 16 4 Page 16 4 or 11 bolts 24 Figure 16 5 Page 16 5 that hold housing together 3 Pull the halves of the housing apart If necessary tap lightly on the spline of the input pinion A CAUTION TO PREVENT DAMAGE TO THE HOUSING MATING SEAL SURFACES USE CAUTION WHEN SEPARATING HALVES 4 Remove input pinion gear 19 Figure 16 4 Page 16 4 or 17 Figure 16 5 Page 16 5 by pulling gear out while rocking intermediate gear assembly Lift intermediate gear assembly and differential gear case unit out simultaneously A CAUTION DO NOT DAMAGE GEARS USE EXTREME CARE WHEN HANDLING THEM REMOVE KEY Figure 16 15 Intermediate Gear Assembly Figure 16 16 Remove Key 5 Use a bearing puller or arbor press to remove bearings 18 Figure 16 4 Page 16 4 or 16 Figure 16 5 Page 16 5 from the input pinion gear If the oil seal 10 is damaged replace it Figures 16 4 or 16 5 Pages 16 4 or 16 5 See also Figure 16 15 Page 16 10 A CAUTION DO NOT REUSE BEARINGS AFTER REMOVING THEM REPLACE BEARINGS WITH NEW ONES Page 16 10 1998 1999 PowerDrive Plus Maintenance and Service Supplement TRANSAXLE Transaxle Disassembly Inspection and Assembly Transaxle Disassembly and Inspe
80. Switch Page 11 20 Reverse Buzzer Page 11 21 Reboot Onboard Computer Page 11 22 DIAGNOSTIC FLOW CHARTS The diagnostic flow charts included in this section may be used as a reference when performing test procedures on the PowerDrive Plus vehicle More detailed system testing instructions follow 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement 11 11 ELECTRICAL SYSTEM AND TESTING Page 11 12 NO CONTINUITY 4 REPLACE F amp R SWITCH VEHICLE DOES NOT OPERATE LOW VOLTAGE READING RECHARGE BATTERIES LTAGE CHECK BATTERY PACK VOLTAGE TEST PROCEDURE 1 CHECK VOLTAGE OUTPUT FROM OBC BLUE WIRE TEST PROCEDURE 2 READING CHECK VOLTAGE AT MAIN SOLENOID ACTIVATING COIL CHECK F amp R SWITCH CONTINUITY TEST PROCEDURE 16 000 TEST PROCEDURE 3 VOLTAGE READING CORRECT SOLENOID CLICKS VOLTAGE READING CORRECT NO VOLTAGE VOLTAGE READING CORRECT VOLTAGE READING CORRECT SOLENOID DOES NOT CLICK REPLACE SOLENOID REPLACE CONTROLLER CHECK MAIN SOLENOID FOR CONTINUITY Diagnostic Flow Charts CHECK KEY SWITCH AND ACCELERATOR LIMIT SWITCH CIRCUIT NO VOLTAGE REPAIR OR REPLACE WIRING TEST PROCEDURE 9 KEY OR LIMIT SWITCH AS REQUIRED CHECK TOW RUN SWITCH CIRCUIT
81. TEM TO BE ENERGIZED MAKE SURE CAPACITORS ARE DISCHARGED PLACE THE TOW RUN SWITCH IN THE TOW POSITION DISCONNECT BATTERY WIRES PLACE FORWARD REVERSE ROCKER SWITCH IN REVERSE AND LISTEN FOR THE REVERSE BUZZER IF THE REVERSE BUZZER DOES NOT SOUND THE CAPACITORS ARE DISCHARGED IF THE REVERSE BUZZER SOUNDS TURN THE KEY SWITCH ON AND DEPRESS THE ACCELERATOR PEDAL UNTIL THE BUZZER CAN NO LONGER BE HEARD DO NOT WEAR LOOSE CLOTHING REMOVE JEWELRY SUCH AS RINGS WATCHES CHAINS ETC BEFORE SERVICING VEHICLE ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CONNECTIONS WHEN BATTERIES ARE CONNECTED USE EXTREME CAUTION TO AVOID SHORT CIRCUITS IN COMPONENTS OR WIRING TO AVOID UNINTENTIONALLY STARTING THE VEHICLE DISCONNECT BATTERIES AS SHOWN IN FIGURE 15 1 PAGE 15 2 GENERAL INFORMATION The PowerDrive Plus vehicle is equipped with a 48 volt DC shunt wound reversible traction motor The shunt wound motor is designed for use on the PowerDrive Plus vehicle only Club Car recommends motors requiring major repair be sent to a qualified motor repair shop However there are many relatively simple tasks that can be performed by a technician with general knowledge and experience in electric motor repair 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement 15 1 External Motor Testing FRONT OF VEHICLE PLACE TOW SWITCH IN THE TOW POSITION BEFORE REMOVE N
82. TMENT Each of the adjustments listed in the following WARNING affects multi step potentiometer adjustment To ensure proper vehicle operation if any one item requires adjustment all must be checked and adjusted if necessary in the order listed A WARNING e TO PROPERLY ADJUST MULTI STEP POTENTIOMETER CHECK AND ADJUST IF NECESSARY THE FOLLOWING ITEMS N THE ORDER LISTED BRAKE PEDAL AND CABLE ADJUSTMENT SEE SECTION 5 ACCELERATOR AND BRAKE PEDAL GROUP IN MAINTENANCE AND SERVICE MANUAL ACCELERATOR ROD ADJUSTMENT SEE SECTION 5 ACCELERATOR AND BRAKE PEDAL GROUP IN MAINTENANCE AND SERVICE MANUAL ACCELERATOR PEDAL STOP ADJUSTMENT SEE SECTION 5 ACCELERATOR AND BRAKE PEDAL GROUP IN MAINTENANCE AND SERVICE MANUAL PARK BRAKE ADJUSTMENT SEE SECTION 5 ACCELERATOR AND BRAKE PEDAL GROUP IN MAINTENANCE AND SERVICE MANUAL e FAILURE TO CHECK ALL ADJUSTMENTS IN THE ORDER LISTED COULD RESULT IN IMPROPER VEHICLE OPERATION PROPERTY DAMAGE OR SEVERE PERSONAL INJURY RESISTORS Resistor Removal 1 Push locking tabs out of the retainers and remove multi step potentiometer cover 1 Figure 12 12 Page 12 16 2 Remove the two thread rolling screws 32 and resistor protector cover 39 from the multi step potentiome ter Figure 12 12 Page 12 16 3 Remove the seven 1 4 20 hex nuts securing the resistors to the multi step potentiometer 4 Remove the six resistors from the multi step potentiometer Resistor Installatio
83. TTACHMENT TOOL CLUB CAR PART NO 1012812 4 N LDL IAS BEARING PULLER CLUB CAR PART NO 1012811 a y Figure 15 12 Bearing Removal Figure 15 13 Guide Ring Removal A CAUTION IF THE MOTOR IS BEING ASSEMBLED WITH THE ARMATURE STANDING ON END AS THE COMMUTATOR IS POSITIONED MAKE SURE THE BRUSHES ARE HELD BACK DO NOT ALLOW THE BRUSHES TO SUPPORT THE WEIGHT OF THE STATOR SHELL THE BRUSHES CAN BE EASILY DAMAGED BY THIS WEIGHT 6 1 Attach the end shield 10 to bearing retainer 16 by aligning the two holes in the bearing retainer with the two mating holes in the end shield and installing the screws 9 Figure 15 8 Page 15 7 Tighten the screws to 17 1 9 N m See following NOTE NOTE e USE A LONG SCREW WITH SAME THREAD SPECIFICATIONS AS MOUNTING SCREWS TO MAINTAIN HOLE ALIGNMENT WHILE STARTING FIRST MOUNTING SCREW FIGURE 15 15 PAGE 15 13 6 2 Align the match marks on the end shield and the stator shell then install the four screws 8 Figure 15 8 Page 15 7 Tighten the screws to 90 in Ib 10 N m NOTE MAKE SURE THE MOTOR SPEED SENSOR LEAD LOCATED ON THE END SHIELD IS ALIGNED WITH THE F2 AND A2 TERMINALS ON THE MOTOR HOUSING 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 15 11 Motor Installation Motor Assembly Continued 7 Make sure the armature turns freely If it doesn t turn fr
84. The PowerDrive battery charger transformer has two coils a primary coil and a secondary coil Figure 14 16 Page 14 17 Primary Coil 1 Disconnect both AC and DC cords and remove charger cover See preceding WARNING 2 Disconnect terminals from transformer tan primary leads 4 and 6 Figure 14 16 Page 14 17 3 Place the continuity tester leads on the disconnected primary coil leads Tester should register continuity If tester does not register continuity replace the transformer Secondary Coil 1 Disconnect both AC and DC cords and remove charger cover See preceding WARNING 2 Remove the transformer tan secondary coil lead 1 from the upper terminal of the heat sink assembly Fig ure 14 16 Page 14 17 See following DANGER DANGER DO NOT ALLOW SECONDARY COIL LEADS TO TOUCH ONE ANOTHER THERE ARE APPROXIMATELY 120 VOLTS PRESENT 3 Remove the other transformer tan secondary coil lead 5 from the bottom terminal of the heat sink assem bly and place the tester clip on the ammeter bus bar 7 Figure 14 16 Page 14 17 Place the continuity leads on each tan secondary coil lead Tester should register continuity If tester does not register continuity replace transformer Be sure the fuse is intact and not blown Voltage Suppressor Failed Closed 1 Disconnect both AC and DC plugs See preceding WARNING 2 Connect red lead of multimeter with alligator clips to the positive pin of the DC plug 3
85. USES VISIBLE ON FRONT OF CHARGER DETERMINE CAUSE REPLACE FUSE CHARGE BATTERIES CORRECT OR TIGHTEN WIRING IS FUSE BLOWN REMOVE CHARGER COVER AND LOOK FOR LOOSE CONNECTIONS AND PROPER WIRING CHARGE BATTERIES IS WIRING CORRECT AND TIGHT BY PASS CHARGER RELAY AS DESCRIBED IN TEST PROCEDURE 6 PAGE 14 16 REPLACE CHARGER THAT MAY BE MALFUNCTIONING WITH ONE THAT IS KNOWN TO BE WORKING PROPERLY DOES CHARGER OPERATE PROPERLY COLUMN ONE CONTINUED ON NEXT PAGE E PROBLEM IS IN VEHICLE CHARGING CIRCUIT LOOK FOR LOOSE CONNECTION OBC MAY BE IN POWER DOWN MODE DISCONNECT CHARGER DC PLUG AND DRIVE VEHICLE FOR A FEW MINUTES RECONNECT CHARGER PLUG DOES CHARGER ACTIVATE OBC PROGRAM MAY BE LOCKED UP REMOVE DC CORD FROM RECEPTACLE REBOOT COMPUTER SEE SECTION 11 TEST PROCEDURE 18 REBOOT OBC PAGE 11 22 DOES CHARGER ACTIVATE NO CHECK SENSE LEAD FUSE TO SEE IF BLOWN IS FUSE BLOWN NO CHECK OBC FUSE IN RED WIRE COLUMN TWO CONTINUED ON NEXT PAGE Figure 14 7 Flow Chart Continued Troubleshooting CHARGE BATTERIES CHARGE BATTERIES DETERMINE CAUSE REPLACE FUSE CHARGE BATTERIES 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14 11 14 POWERDRIVE BATTERY CHARGER Test Procedures COLUMN O
86. Up to 134 inches 3 4 mm E l 134 142 inches 3 4 3 6 mm SHIMS REQUIRED 134 142 inches ee 155 inches 3 8 3 9 mm 150 155 inches 3 8 3 9 mm Figure 16 21 Depth Gauge TRANSAXLE INSTALLATION Read DANGER and WARNING on page 16 1 1 If using a chain hoist raise the vehicle and place transaxle in position on the jackstands If using a floor jack lower the jackstands to their lowest settings and place the transaxle in position on the jackstands 2 Align the center hole in the saddle of the transaxle with the alignment pin in the leaf spring assembly 3 Install the two U bolts lockwashers and nuts Tighten the nuts to 25 ft lb 34 N m Tighten the U bolt nuts so an equal amount of thread is visible on each leg of the bolt Page 16 14 1998 1999 PowerDrive Plus Maintenance and Service Supplement TRANSAXLE Transaxle Installation Transaxle Installation Continued 4 Install the motor See Section 15 Motor 5 If using a chain hoist lower the vehicle while guiding the leaf springs into the rear spring shackles If using a floor jack raise the differential while guiding the leaf springs into the rear spring shackles Then raise the jack stands to support the transaxle 6 Reconnect the four motor wires Tighten the retaining nuts to 65 in Ib 7 3 N m using two wrenches to pre vent the motor studs from turning See following NOTE NOTE IF THE MOTOR WIRES WERE NOT TAGG
87. VED EYE PROTECTION WHILE SERVICING VEHICLE WEAR A FULL FACE SHIELD AND RUBBER GLOVES WHEN WORKING WITH BATTERIES TURN KEY SWITCH OFF PLACE FORWARD REVERSE ROCKER SWITCH IN NEUTRAL AND REMOVE KEY PRIOR TO SERVICING DO NOT WEAR LOOSE CLOTHING REMOVE JEWELRY SUCH AS RINGS WATCHES CHAINS ETC BEFORE SERVICING VEHICLE ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CONNECTIONS BEFORE PERFORMING TESTS OR REPAIRS MAKE SURE CAPACITORS ARE DISCHARGED PLACE TOW RUN SWITCH IN TOW DISCONNECT BATTERY WIRES PLACE FORWARD REVERSE ROCKER SWITCH IN REVERSE AND LISTEN FOR THE REVERSE BUZZER IF THE BUZZER DOES NOT SOUND THE CAPACITORS ARE DISCHARGED IF THE REVERSE BUZZER SOUNDS TURN THE KEY SWITCH ON AND DEPRESS THE ACCELERATOR PEDAL UNTIL THE BUZZER CAN NO LONGER BE HEARD TO AVOID UNINTENTIONALLY STARTING THE VEHICLE PLACE THE TOW RUN SWITCH IN THE TOW POSITION AND DISCONNECT BATTERIES AS SHOWN IN FIGURE 13 5 PAGE 13 4 GENERAL INFORMATION The batteries supplied with a PowerDrive Plus vehicle are different from those supplied with automobiles The out ward appearance of these two batteries is similar but the operating characteristics are very different The Power Drive Plus vehicle battery is known as a deep cycle battery and the automotive battery is known as a starting lighting and ignition SLI battery They should never be substituted for one another An automotive
88. WHILE SERVICING VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES PLACE THE TOW RUN SWITCH IN THE TOW POSITION BEFORE CONNECTING OR DISCONNECTING BATTERY WIRES BEFORE PERFORMING ANY TESTS OR REPAIRS MAKE SURE CAPACITORS ARE DISCHARGED PLACE THE TOW RUN SWITCH IN THE TOW POSITION DISCONNECT BATTERY WIRES PLACE FORWARD REVERSE ROCKER SWITCH IN REVERSE AND LISTEN FOR THE REVERSE BUZZER IF THE REVERSE BUZZER DOES NOT SOUND THE CAPACITORS ARE DISCHARGED IF THE REVERSE BUZZER SOUNDS TURN THE KEY SWITCH ON AND DEPRESS THE ACCELERATOR PEDAL UNTIL THE BUZZER CAN NO LONGER BE HEARD DO NOT WEAR LOOSE CLOTHING REMOVE JEWELRY SUCH AS RINGS WATCHES CHAINS ETC BEFORE SERVICING VEHICLE ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CONNECTIONS WHEN BATTERIES ARE CONNECTED USE EXTREME CAUTION TO AVOID SHORT CIRCUITS IN COMPONENTS OR WIRING TO AVOID UNINTENTIONALLY STARTING THE VEHICLE DISCONNECT BATTERIES AS SHOWN IN FIGURE 12 1 PAGE 12 2 WHEN PERFORMING TESTS THAT DO NOT REQUIRE THE ELECTRICAL SYSTEM TO BE ENERGIZED A 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 Plus Vehicle Maintenance and Service Supplement 12 1 ELECTRICAL CO
89. absorber Compress the shock absorber pushing upwards to move it out of the way 7 Remove the nuts and bolts mounting the rear leaf springs to the shackles Figure 15 4 Page 15 4 8 To gain easier access to the motor lower the transaxle as low as it will go If more room is needed remove the jack from beneath the transaxle and allow the springs to rest on the floor Figure 15 4 Page 15 4 9 Remove the four bolts that mount the motor to the transaxle Figure 15 17 Page 15 13 A CAUTION DO NOT PLACE FINGERS OR HANDS UNDER MOTOR DURING REMOVAL SEVERE INJURY COULD RESULT IF FINGERS OR HANDS ARE CAUGHT BETWEEN MOTOR AND AXLE TUBE 10 Carefully slide the motor away from the transaxle until the motor spline disengages the pinion and then remove the motor from the vehicle Figure 15 4 Lower Axle Motor Disassembly 1 Before beginning disassembly place match marks on the motor end shield and stator shell then place the motor in a vice with wooden blocks as shown Figure 15 5 Page 15 5 Remove the four bolts 8 securing the end shield 10 to the stator shell 2 Figure 15 5 Page 15 5 Remove the two screws 9 attaching the end shield to the bearing retainer Figure 15 5 Page 15 5 Slide the armature 17 out of the opposite end of the stator shell Figure 15 5 Page 15 5 Remove two screws 11 attaching brush rigging 12 to the stator shell 2 Figure 15 8 Page 15 7 3 M
90. achine to bat tery No 1 positive post and connect the negative lead to battery No 6 negative post Record reading from discharge machine See WARNING on page 11 11 2 Record the voltage reading of battery pack while under load as displayed on the discharge machine dis charge machine is ON 3 A fully charged set of batteries in good condition should read between 46 49 volts while under load 4 A reading of 32 46 volts indicates discharged or defective batteries Each battery should be checked with a multimeter while under load 5 Areading of 32 volts or less will not activate discharge machine Batteries are deeply discharged or defective 6 Recording the battery pack voltage reading while under load provides a more accurate diagnosis of the con dition of the batteries When the discharge machine is ON it places the battery pack under load and many times can help determine if one or more batteries in the set are defective Testing battery voltage while the batteries are not under load will not always indicate the true condition of the batteries 7 If batteries test okay and vehicle runs slow test the dynamic braking solenoid for proper operation 8 Drive vehicle approximately 100 ft with the accelerator pedal half way depressed to the floor Stop the vehicle and check the resistor coil on the dynamic braking solenoid by placing hand close to but not touching the coil If the coil is hot replace the solenoid A WARNING DO
91. ad 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 Ifreading 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 Check wires in the plug to make sure none are broken at the terminal pin crimp
92. age 11 24 speed controller After a short time replace the lead and restart the OBC and discharge the Restart OBC by driving vehicle or by connecting charger DC plug from batteries Recharge batteries Figure 11 15 Flow Chart CDM Troubleshooting Guide 1998 1999 PowerDrive Plus Maintenance and Service Supplement SECTION 12 ELECTRICAL COMPONENTS DANGER 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 ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL MECHANICAL AND ELECTRICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNING STATEMENTS IN THIS MANUAL ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION
93. age 11 6 2 Solid State Speed Control Circuit Figure 11 5 Page 11 8 and 3 Tow Switch Circuit Figure 11 6 Page 11 9 Page 11 4 1998 1999 PowerDrive Plus Maintenance and Service Supplement ELECTRICAL SYSTEM AND TESTING Electrical Circuits 1 1 Supplies 48 volt input to controller through the red wire to keep capacitors inside the controller charged Supplies voltage when key switch is either ON or OFF if TOW RUN switch is in RUN position Voltage input to controller capacitors is shut off when TOW RUN switch is in TOW position PIN 1 RED WIRE Pin 2 completes circuit to controller through orange white wire when TOW RUN switch is in PINA RUN position Activates electronic components in the controller to allow the vehicle to operate With the TOW RUN switch in the RUN position the key switch ON and the accelerator pedal PIN 3 GREEN WHT WIRE depressed limit switch closed Pin 3 completes circuit through the green white wire to controller which actuates controller and starts vehicle When F amp R switch is in FORWARD Pin 4 completes circuit to controller through white wire to operate vehicle in forward direction When F amp R switch is in REVERSE Pin 5 completes circuit to controller through blue wire to PINS BLUE WIRE operate vehicle in reverse direction PIN 6 If the vehicle is not charged for three days the onboard computer powers down the electrical YELLOW system to reduce batter
94. ard computer Use the following procedure to review the data stored in the CDM The value currently displayed will be F1 battery voltage To view F2 press and hold the button on the CDM When Func 2 appears in the display window release the button The value for F2 will then be displayed To view F3 press and hold the button on the CDM until Func 3 appears in the display window Release the button The value for F3 will be displayed 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement 11 23 ELECTRICAL SYSTEM AND TESTING To view F4 press and hold the button on the CDM until Func 4 appears in the display window Release the button The value for F4 will be displayed CDM Troubleshooting Guide CDM TROUBLESHOOTING GUIDE Use the following chart as a starting point for troubleshooting problems with communication between the CDM and onboard computer Contact your Club Car representative for more comprehensive information Defective Dash Light OBC Does Not Communicate With CDM Dead CDM battery Faulty CDM unit Replace CDM battery Replace CDM Faulty OBC Replace OBC Tow Run switch in TOW position OBC program is locked up OBCisina powerdown mode More than 75 EUs or 7596 of energy removed Remove battery lead P
95. arge the batteries before performing the hydrometer test 2 Remove the vent cap Using a battery thermometer CLUB CAR part No 1011767 record the electrolyte tem perature of the No 2 cell 3 Squeeze the rubber bulb of the hydrometer and insert into the cell Slowly release the bulb drawing electro lyte up into the glass tube of the hydrometer 4 When the float rises off the bottom adjust the electrolyte level so that the float rides free of the bottom but does not strike the top of the glass tube Remove the hydrometer from the cell and release the pressure from the bulb 5 Hold the hydrometer vertically ensuring that the float is not touching the sides of the barrel Hold the hydrometer at eye level and read the scale at the level of electrolyte Figure 13 8 Page 13 10 6 Record the reading Return the electrolyte to the cell from which it was taken Replace vent cap Page 13 8 1998 1999 PowerDrive Plus Maintenance and Service Supplement BATTERIES Battery Testing BATTERY TROUBLESHOOTING CHART Vehicle not operating to expectation Fully Charge Batteries Battery Charger Test Page 13 8 Reading 8 Amps or more Reading below 8 Amps Check vehicle electrical system and charger for problems See Troubleshooting Guide On Charge Voltage Test Section 14 PowerDrive Battery Charger Page 13 8 If problem is not found go to on charge voltage test All readings above 9 8V and within 0 7V Readi below 9 8V b
96. ark the brush terminal posts A1 and 2 13 to identify their positions in the stator shell and winding assembly then remove the nuts 6 and flat washers 5 Figure 15 8 Page 15 7 From the outside push the posts through the stator shell wall into the interior of the stator shell and winding assembly 7 Carefully remove the brush rigging and the terminal posts from the stator shell 8 To remove brush springs 14 from the rigging lift the spring extensions out and over the brush mounts and then slide the springs off their mounting tabs Figure 15 6 Page 15 5 Page 15 4 1998 1999 PowerDrive Plus Maintenance and Service Supplement Testing and Inspecting Individual Components ARMATURE Figure 15 5 Motor Disassembly Figure 15 6 Brush Spring Removal TESTING AND INSPECTING INDIVIDUAL COMPONENTS Read DANGER and WARNING on page 15 1 ARMATURE 1 Disassemble the motor and carefully inspect the armature for the following defects Burned charred or cracked insulation Improperly cured varnish Thrown solder Flared armature windings Damaged armature core laminations Worn burned or glazed commutators Dirty or oily commutators Raised commutator bars Worn armature bearing or shaft A dirty or oily commutator should be cleaned and wiped dry Abnormalities identified during the inspection can help determine original cause of failure Slight roughness of the commutator can be polished
97. at sink assembly Figures 14 4 and 14 5 Pages 14 7 and 14 8 Tighten nut to 18 in lb 2 0 N m 3 Connect the other secondary transformer lead tan to the bottom terminal post of the heat sink assembly Figures 14 4 and 14 5 Pages 14 7 and 14 8 Tighten nut to 18 in lb 2 0 N m 4 Connect one secondary transformer lead black to one terminal of the fuse assembly Figures 14 4 and 14 5 Pages 14 7 and 14 8 Tighten nut to 22 2 5 N m 5 Connect the other secondary transformer lead black to the remaining terminal of the fuse assembly Fig ures 14 4 and 14 5 Pages 14 7 and 14 8 Tighten nut to 22 in lb 2 5 N m 6 Connect the tan primary lead to the charger relay Figures 14 4 and 14 5 Pages 14 7 and 14 8 7 Connect other tan primary lead to white wire from AC cord Figures 14 4 and 14 5 Pages 14 7 and 14 8 8 Replace charger cover and check charger for proper operation AMMETER Ammeter Removal 1 2 3 4 Remove charger cover See preceding WARNING Disconnect black wire from DC cord 5 and bus bar 3 from ammeter Figure 14 20 Page 14 23 Remove the two nuts 2 that secure the ammeter to the charger face Figure 14 20 Page 14 23 Remove the ammeter from the face of the charger Ammeter Installation 1 2 3 Place the ammeter in position in the charger face Figure 14 20 Page 14 23 Install the nuts 2 and tighten until ammeter is firmly secured Figure 14 20 Page 14 23 Connect t
98. ate of charge Any battery with a specific gravity lower than 1 250 will need a catch up charge If the problem con tinues after a catch up charge has been performed refer to Section 14 PowerDrive Battery Charger DEEP DISCHARGE Never discharge batteries to the point the vehicle will no longer operate This will considerably shorten the cycle life of the batteries and may permanently damage the batteries It is possible the batteries will not accept a recharge if they are completely discharged The deeper the discharge the harder it is on the batteries For this reason it is recommended that PowerDrive Plus vehicle batteries be charged after each use provided the charge cycle will not be interrupted and the charger will be allowed to shut off automatically Placing the batteries on charge after each use reduces the depth of discharge and prolongs battery life EARLY EXCESSIVE DISCHARGING When vehicle batteries are new they do not reach their full capacity until they have been used and recharged 20 to 50 times If they are excessively discharged early in their life their effective service life will be shortened It is advis able to limit the use of any vehicle with new batteries for at least the first four weeks and then gradually increase their range INCOMING AC SERVICE Make sure the incoming AC line service is sufficient If circuit breakers are tripping fuses blow during the night or the charger does not give the required starting rat
99. back into the electrolyte to make sulfuric acid 504 The oxygen returns to the positive plate to make lead dioxide PbO Figure 13 4 Page 13 2 The result is a charged battery that is again capable of generating electricity Figure 13 1 Page 13 2 COMMON MISCONCEPTIONS ABOUT BATTERIES The chart below describes some of the more common misconceptions that are associated with the PowerDrive Plus vehicle batteries and battery care PROBLEM MISCONCEPTION AND REALITY Deep Discharge Misconception This vehicle is running slowly but we can run it until it stops Reality This statement is wrong Avoid deep discharge of batteries whenever possible See Battery Charging Page 13 6 Early Excessive Misconception These are new batteries They can run all day Discharging Reality This statement is wrong also New batteries do not reach their full capacity until they have been used and recharged 20 to 50 times Mineral Content Misconception Tap water will do for our batteries Reality Your tap water might be OK but have it checked first See Battery Care Page 13 5 Self Discharge Misconception Dirt and corrosion on the battery won t hurt anything Reality Wrong again Dirt and corrosion might provide a path for current to flow and allow the batteries to self discharge See Battery Care Page 13 5 Overwatering Misconception Batteries can be filled to the level indicator at night so it won t have to be d
100. battery has to deliver high cranking currents of 300 400 amperes at a sufficient voltage for several seconds and maintain an accessory load of 10 25 amperes in stop and go driving The energy removed from an automotive battery is immediately replaced by the alternator or generator As a result the automotive battery oper ates at 90 to 100 of full charge at all times 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 13 1 BATTERIES General Information General Information Continued CHARGED BATTERY Figure 13 1 Charged Battery DISCHARGED BATTERY BATTERY CHARGING Figure 13 3 Discharged Battery Figure 13 4 Charging Battery The batteries supplied with an electric vehicle must supply 100 of the energy required to operate the vehicle These batteries therefore receive deep discharge down to 30 to 40 of their full charge capacity Then they must be recharged hence the name deep cycle The average amperage draw is considered to be 56 amps on a 48 volt vehicle although it varies greatly depending on the vehicle and how it is operated PowerDrive Plus vehicle batter ies are specifically designed to handle this type of service The rechargeable lead acid battery turns chemical energy into electrical energy and vice versa The main active ele ments within a battery are the positive plates the negative plates and the electrolyte sulfuric acid Another very important element
101. battery voltage If the voltage reading is 48 volts and the solenoid does not click replace the solenoid 3 If the voltage reading is zero volts replace speed controller See WARNING on page 11 11 Test Procedure 4 Multi Step Potentiometer Wiper Switch Voltage 1 Place Tow Run switch in RUN Using a multimeter set to 20 volts DC place black lead on battery No 6 negative post and place red lead with insulation probe on purple wire at a point between the six pin connector and wiper switch The reading should be approximately 3 75 volts See WARNING on page 11 11 2 If reading is zero volts check the purple wire continuity from the connector to the controller the purple wire continuity from the connector to the wiper switch and the six pin connector at the wiper switch If all of the continuity readings are correct replace the controller 3 With multimeter set to 200 volts DC place the red lead on battery No 1 positive post and the black lead with insulation probe on the white black wire at a position between the six pin connector and the wiper switch The reading should be approximately 48 50 volts 4 If reading is zero volts check white black wire continuity from six pin connector to 23 pin connector Check white black wire continuity from six pin connector to wiper switch Check terminal positions in six pin connector at the wiper switch If all of the continuity readings are correct replace the speed controller 5 With mu
102. ck state of charge The Power Circuit consists of Battery Pack six eight volt batteries Solid State Speed Controller Electric Motor Solenoid Contacts Energy Displacement Module Resistor Coil All 6 Gauge Power Wires 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 11 7 ELECTRICAL SYSTEM AND TESTING REVERSE BUZZER PIN 8 WHT BLK WIRE PIN 7 YEL BLK WIRE PIN 5 BLUE WIRE PIN 4 WHITE WIRE m 10 20 30 40 50 60 70 99 109 119 129 130 14915 01 o o o o ofofo DYNAMIC BRAKING SOLENOID PIN 15 RED GREEN WIRE PIN 14 LIGHT GREEN WIRE PIN 12 BROWN WIRE PIN 11 BLUE WHITE WIRE PIN 10 ORANGE WIRE 9 PURPLE WIRE PIN 16 BLACK WIRE Figure 11 5 Solid State Speed Control Circuit FORWARD REVERSE SWITCH MULTI STEP POTENTIOMETER Page 11 8 1998 1999 PowerDrive Plus Maintenance and Service Supplement CONTROLLER Electrical Circuits MAIN SOLENOID ELECTRICAL SYSTEM AND TESTING Electrical Circuits NY KEY MULTI STEP fff SWITCH TOW POTENTIOMETER SWITCH TWO PIN CONNECTOR SLIHWGQ3H ee Q e SIX PIN Cz CONNECTOR lt lt ONBOARD 2 PIN 3 GRN WHT WIRE COMPUTER K 2 LE i 20 30 40 50 60 70 1 90100110 120 130 140150 A N N if X 06 yl toy MAIN SOLENOID ONBOARD COMPUTER CONTROLLER
103. connect the wires from the key switch Do not allow wires to touch 6 From the back of the dash panel push down on the retaining tabs surrounding the key switch 4 and remove the key switch cap 8 Hold the key switch and remove the switch retaining nut 6 from the outside of the dash panel Figure 12 2 Page 12 3 Page 12 2 1998 1999 PowerDrive Plus Maintenance and Service Supplement ELECTRICAL COMPONENTS Forward Reverse F amp R Rocker Switch Figure 12 2 Key Switch Key Switch Installation 1 Position key switch in the center dash then install and tighten the switch retaining nut to 40 in Ib 4 5 N m Press the plastic cap 8 into place on the outside of the center dash Figure 12 2 Page 12 3 2 Connect the wires to the key switch terminals see Section 11 Figure 11 2 Page 11 3 and then coat the terminals with Battery Protector Spray Club Car Part No 1014305 3 Install center dash by reversing removal procedure Make sure key switch terminals 7 do not touch frame and the center dash panel is properly seated and snapped into place Figure 12 2 Page 12 3 4 Reconnect battery wires positive wire first and tighten to 110 in lb 12 4 N m Place Tow Run switch in RUN FORWARD REVERSE F amp R ROCKER SWITCH Read DANGER and WARNING on page 12 1 Testing the Forward Reverse rocker switch See Test Procedure 16 Section 11 Page 11 20 Forward Reverse F amp R Rocker Switch Removal 1 Remove three
104. ction Continued 6 To disassemble the intermediate gear assembly press off together the bearing 18 Figure 16 4 Page 16 4 or 16 Figure 16 5 Page 16 5 and the gear 23 Figure 16 4 Page 16 4 or 19 Figure 16 5 Page 16 5 See also Figure 16 15 Page 16 10 7 Type K transaxles Remove key 22 Figure 16 4 Page 16 4 See also Figure 16 16 Page 16 10 8 Press the bearing 20 Figure 16 4 Page 16 4 or 18 Figure 16 5 Page 16 5 off the intermediate gear assembly TO SEPARATE HOUSING IT MAY BE NECESSARY TO INSERT HEX HEAD BOLTS INTO HOUSING AND TAP LIGHTLY Figure 16 17 Lock Plate Type K Only Figure 16 18 Separate Housing 9 Disassemble the differential gear case 9 1 Type K transaxles Bend the bolt lock plates 29 down onto the ring gear 30 Figure 16 4 Page 16 4 See also Figure 16 17 Page 16 11 9 2 Remove eight hex bolts 28 Figure 16 4 Page 16 4 or four hex bolts 33 Figure 16 5 Page 16 5 that secure the ring gear to the differential case 9 3 Remove the ring gear Retain dowel pin from between the ring gear and differential case for reassembly 9 4 Separate the differential gear case housing If necessary reinstall two of the hex bolts removed previ ously in step 9 2 into the differential gear unit and while holding the unit slightly above the work area lightly tap the bolt heads Figure 16 18 Page 16 11 Remove the two bolts 9 5 Remove the differential pin 31 by push
105. cure the 10 gauge black wire from the computer 5 and the 10 gauge black wire to the receptacle Figure 12 8 Page 12 10 2 Remove the fuse link 6 from the charger receptacle Figure 12 8 Page 12 10 Receptacle Fuse Link Installation 1 Insert the two fuse link mounting posts into the mounting holes in the charger receptacle 2 Place the two 10 gauge black wires in their original positions on the fuse link mounting posts 3 Install nuts 2 on fuse link mounting posts and tighten to 19 2 1 N m Figure 12 8 Page 12 10 Page 12 10 1998 1999 PowerDrive Plus Maintenance and Service Supplement ELECTRICAL COMPONENTS Multi step Potentiometer MULTI STEP POTENTIOMETER Read DANGER and WARNING on page 12 1 Testing the Multi step Potentiometer See Section 11 Test Procedure 4 Page 11 18 Multi step Potentiometer Removal 1 Place Tow Run switch in the TOW position and disconnect the batteries Figure 12 1 Page 12 2 2 Remove the battery wire connecting batteries No 5 and No 6 and the battery wire connecting batteries No 5 and No 4 Figure 12 1 Page 12 2 3 Remove the hold down bracket from the No 5 and No 6 batteries and then remove the No 5 and No 6 bat teries from the vehicle Figure 12 1 Page 12 2 4 Slide back the ball stud retainer on the potentiometer end of the accelerator rod 1 and disconnect the accel erator rod from the multi step potentiometer Figure 12 9 Page 12 12 5 Disconnect the six
106. ds over 75 the vehicle Battery Warning Light should be illuminated the vehicle batteries 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 most useful in making sure that 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 and the first time a set of batter ies is charged after the batteries have been disconnected and reconnected A problem may exist if persistent DVDT readings are obtained Page 11 22 1998 1999 PowerDrive Plus Maintenance and Service Supplement ELECTRICAL SYSTEM AND TESTING The Communication Display Module CDM 4 Indicates the last charge cycle was normal 8 Indicates the charger ran for sixteen hours and shut itself off without completing the charge cycle This means there may be a problem in the charge circuit The CDM also has a low battery signal wh
107. dure 8 Page 14 17 5 Single charger fuse link blows 1 Diode failed Test Procedure 4 A Page 14 14 2 Loose internal fuse connection Tighten connection 6 Both charger fuse links blow or recepta 1 Battery is wired in reverse polarity Test Procedure 4 B Page 14 15 cle fuse link blows 2 DC cord is wired in reverse polarity Test Procedure 4 B Page 14 15 3 Both diodes failed Test Procedure 4 B Page 14 15 7 Charger output is low 1 One diode failed Test Procedure 4 A Page 14 14 2 Transformer coil short circuit failure Test Procedure 6 Page 14 16 3 Onboard computer malfunction Test Procedure 2 Page 14 13 8 Chargerturns off too soon 1 AC power supply was shut off Test Procedure 3 Page 14 14 2 Onboard computer malfunction Test Procedure 2 Page 14 13 3 Batteries may be fully charged Test Procedure 7 Page 14 17 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14 9 POWERDRIVE BATTERY CHARGER Troubleshooting POWERDRIVE BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Charger goes to 16 hour time out Onboard computer malfunction Test Procedure 2 Page 14 13 Extremely discharged batteries or Recharge batteries cold temperature Defective battery Section 13 Batteries AC line fuse or circuit breaker blows AC cord is shorted Test Procedure 8 Page 14 17 Failed transformer Test Procedure 6 Page 14 16 Battery trouble light illuminates
108. e 12 7 Page 12 8 Tighten nuts 1 to 9 ft lb 12 2 N m Tighten nut 10 to 32 in lb 3 6 N m See Section 11 Figure 11 1 Page 11 2 for wire destinations 3 Install rear body access door 4 Reconnect battery cables positive cable first and tighten to 110 in lb 12 4 N m Figure 12 1 Page 12 2 Place Tow Run switch in RUN CHARGER RECEPTACLE ASSEMBLY Read DANGER and WARNING on page 12 1 Testing the Charger Receptacle See Test Procedure 13 Section 11 Page 11 19 NOTE DISASSEMBLY OF THE CHARGER RECEPTACLE FOR THE PURPOSE OF REMOVAL OR INSTALLATION IS NOT RECOMMENDED Charger Receptacle Removal Place Tow Run switch in the TOW position and disconnect the batteries See Figure 12 1 Page 12 2 Remove the 10 gauge red wire 4 from the positive post of battery No 1 Figure 12 8 Page 12 10 Remove black 10 gauge OBC wire 5 from charger receptacle assembly Figure 12 8 Page 12 10 Disconnect the gray wire 9 from the receptacle at the yellow fuse holder Figure 12 8 Page 12 10 Ur BU NEC Remove the four screws 1 that secure the charger receptacle bezel 8 to the receptacle backing plate and to the vehicle body Figure 12 8 Page 12 10 6 Move the receptacle assembly toward the front of the vehicle and tilt receptacle upwards in order for the receptacle to pass through the hole in the vehicle body Charger Receptacle Installation 1 Insert the 10 gauge red wire 4 and the 18 gauge gray wire
109. e gray wire fuse holder to the charger receptacle Connect black 10 and 6 gauge wires 9 and 14 to controller B terminal Figure 12 6 Page 12 8 Plug the six pin connector 16 into the OBC Figure 12 6 Page 12 8 Install the rear body access door ON Reconnect battery cables positive cable first and tighten to 110 in lb 12 4 N m Figure 12 1 Page 12 2 Place Tow Run switch in RUN TYPICAL TYPICAL 3 PLACES Figure 12 7 Speed Controller Page 12 8 1998 1999 PowerDrive Plus Maintenance and Service Supplement ELECTRICAL COMPONENTS Solid State Speed Controller SOLID STATE SPEED CONTROLLER Read DANGER and WARNING on page 12 1 Testing the Solid State Speed Controller See Test Procedure 5 Section 11 Page 11 16 Speed Controller Removal Place Tow Run switch in the TOW position and disconnect the batteries See Figure 12 1 Page 12 2 Remove the rear body access door Disconnect all wires from the speed controller 6 Figure 12 7 Page 12 8 ROW Remove the three self tapping screws 17 that hold the controller 6 to the component mounting plate and remove the controller from the vehicle Figure 12 7 Page 12 8 Speed Controller Installation 1 Install the three self tapping screws 17 that hold the controller 6 to the component mounting plate and tighten to 60 in lb 6 7 N m Figure 12 7 Page 12 8 2 Install wires 12 13 14 15 16 and 18 as illustrated in Figur
110. e when perfectly good batteries are put on charge an AC line problem exists The electrical service to your vehicle storage facility should be sufficient to deliver 115 volts mini mum 105 volts maximum 128 volts and 10 7 amps per charger with all the chargers turned on If not consult your local power company or electrical contractor FLEET ROTATION Rotate your vehicles It is very hard on batteries if the last vehicles in at night are the first ones out in the morning Spread the workload evenly giving all vehicles the same amount of use This will keep your fleet in balance and will not overwork certain sets of batteries NOTE WHEN VEHICLES ARE BEING ROTATED THE CLUB CAR CDM COMMUNICATION DISPLAY MODULE CAN BE A VERY HELPFUL SERVICE TOOL MONITORING THE VALUE OF FUNCTION 3 WITH THE CDM SIMPLIFIES VEHICLE USAGE SCHEDULING SEE SECTION 11 PAGE 13 22 NUMBERING VEHICLES AND CHARGERS Return the vehicles to the same charger each night if possible Numbering the vehicles and the chargers and return ing each vehicle to its designated charger each night can significantly reduce the amount of time spent trouble shooting a problem 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 13 7 BATTERIES Battery Testing BATTERY TESTING Read DANGER and WARNING on page 13 1 Four tests have been developed to help diagnose problems with batteries that have not performed as expected Each test becomes pro
111. eading is approximately 48 volts proceed to step 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 Ifthe 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 32 If the reading is approximately 48 volts proceed to step 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 Ifthe 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 Place black lead of multimeter set to 200 volts DC on negative post of battery No 6 and red le
112. economical service it is designed to deliver The following charts provide recommended service intervals for the lubrication and maintenance of the PowerDrive Plus vehicle Note that critical areas such as brake operation accel erator operation steering and tires should be performed daily These checks can easily be performed when moving the vehicle from the storage facility to the starting line Any vehicle that is not functioning properly should be removed from service until it has been repaired 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 10 1 PERIODIC MAINTENANCE Daily Pre Operation Safety Checklist FRONT OF VEHICLE LAN PLACE TOW RUN SWITCH IN p TOW BEFORE DISCONNECTING REMOVE NEGATIVE THESE CABLE FIRST 4 BATTERY CABLES Figure 10 1 Battery Bank for PowerDrive Plus Vehicle DAILY PRE OPERATION SAFETY CHECKLIST Inspect and drive the vehicle Use the Pre operation Checklist and Performance Inspection in Section 3 General Information located in the 1998 1999 DS Maintenance and Service Manual as a guide to check the following items e Vehicle warning decals Brake system Park brake e Reverse warning buzzer Steering and linkages Proper acceleration and maximum speed Batteries Accelerator Switch In addition check the items listed below Tires Visually inspect for wear damage and proper inflation Forward Reverse switch Check for proper operation See Section 3 General Info
113. ed by a qualified motor repair technician The use of proper tools and meth ods is absolutely essential for successful motor reconditioning 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 15 9 MOTOR Motor Assembly Motor Specifications Any rework must be performed by a qualified technician Motor service specifications are listed in the table below ITEM SERVICE LIMIT Commutator diameter minimum 2 265 in 66 675 mm Commutator concentric with armature shaft within 001 in 0 0508 mm Limit depth of cut when machining commutator 005 in 0 127 mm Bar to bar run out should not exceed 0002 in 00508 mm If undercut of segment insulator is less than 016 in 0 406 mm it should be undercut to 031 in 0 8 mm Machined face of Commutator 8 16 micro in Field coil resistance PowerDrive Plus 48 Volt 3 20 Hp 1 32353 34 MOTOR ASSEMBLY Read DANGER and WARNING on page 15 1 1 Ifthe bearing has been removed replace the bearing 11 Press new bearing onto armature Use an arbor press that exerts pressure on inner race only See following NOTE NOTE MAKE SURE THE BEARING RETAINER 16 FIGURE 15 8 PAGE 15 7 IS POSITIONED ON THE ARMATURE SHAFT BEFORE THE BEARING IS PRESSED ON AN ARBOR WITH AN OUTSIDE DIAMETER OF LESS THAN 5 8 IN 16MM SHOULD BE USED TO PRESS THE BEARING ON N Install the brushes See following NOTE NOTE WHEN INSTALLING NEW BRUSHES REMOVE
114. edure 8 diodes Test Proce dure 4A and all connections POSITIVE PIN POSITIVE PIN PULL NEGATIVE PIN NEGATIVE PIN Figure 14 14 DC Plug Test Leads Figure 14 15 DC Plug Reverse Test Leads 4 Ifthe circuit shows continuity in both directions a short circuit exists in the charger DC circuit usually caused by failed diodes See Test Procedure 4 If diodes have not failed check the DC output cord for a short circuit as described in Test Procedure 8 5 Remove the blue wire from the charger relay and check the continuity between the positive and negative pins and the middle pin on the DC plug Figures 14 4 and 14 5 Pages 14 7 and 14 8 There should be no continuity Test Procedure 6 Transformer Failure of the transformer may be caused by aging or a short circuit in adjacent coil turns If the transformer has failed the ammeter would indicate low output or no output however transformer may hum A blown AC line fuse or circuit breaker in the charger and or storage facility may be caused by a failed transformer To test the transformer 1 Disconnect transformer secondary coil leads Nos 1 and 5 from heat sink assembly Figure 14 16 Page 14 17 2 To apply AC power directly to the transformer primary coil the relay must be bypassed 3 To bypass the relay remove the black wire 3 from the circuit breaker and disconnect the tan wire 4 from the relay Connect the tan wire to the circuit breake
115. eely disassemble the motor to find the problem Make sure the bearing is properly seated in the end shield when assembling the motor MOTOR INSTALLATION Read DANGER and WARNING on page 15 1 1 Apply Molykote G lubricant to the female splines of the motor armature shaft 2 Slide the motor onto the transaxle input shaft Rotate the motor until the locating bolt mounting hole on the motor is aligned with its mounting hole in the transaxle case Install the bolt 28 thread in only a few turns with lock washer 27 Figure 15 8 Page 15 7 See also Figure 15 16 Page 15 13 Do not tighten the bolt at this time 3 Install but do not tighten the three 1 4 20 bolts 25 with lock washers 26 that mount the motor to the tran saxle Figure 15 8 Page 15 7 See following CAUTION A CAUTION MAKE SURE THE MOTOR IS PROPERLY SEATED IN THE TRANSAXLE HOUSING 4 Finger tighten the four bolts moving from bolt C to bolts A B and D until the motor is seated With one wheel jacked up so it is off the ground rotate the axle to make sure the motor is not binding on the transaxle input shaft Figure 15 17 Page 15 13 5 Tighten lower 1 4 in bolt C Next tighten bolt A then tighten center bolt B at the top Tighten bolts to 65 in lb 7 3 N m Tighten the 5 16 in bolt D to 155 in Ib 17 5 N m Figure 15 17 Page 15 13 6 Install the motor wires Make sure they are connected to the correct terminals Tighten the termi
116. enoid during dynamic braking which allows current to go through the resistor coil until batteries can accept a regenerative charge PIN 12 BROWN WIRE Pin 11 completes the negative circuit for the main solenoid activating coil through blue white wire and closes solenoid contacts which allows vehicle to operate If there is no vehicle PIN 11 BLUE WHITE WIRE movement when main solenoid engages Pin 11 shuts off voltage to the solenoid after two seconds During normal operation each time accelerator pedal is released Pin 11 shuts off voltage to the solenoid after two seconds Pin 10 completes negative circuit for the reverse buzzer through the orange wire Activates the SIN TOLORANGE WIRE reverse buzzer when F amp R rocker switch is in the REVERSE position PIN 9 PURPLE WIRE Pin 9 provides a constant 5 volt signal to the multi step potentiometer PIN 16 BLACK WIRE Pin 16 completes the negative circuit for the motor speed sensor through the black wire Figure 11 3 23 Pin Connector Plug 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 11 5 ELECTRICAL SYSTEM AND TESTING Electrical Circuits Onboard Computer Circuit The onboard computer OBC circuit performs the following functions 1 aA FWD Provides power to the solenoids Forward Reverse switch controller capacitors and reverse buzzer Powers down the electrical system during long term storage to reduce battery discharge Activates re
117. ent and underside of vehicle General Vehicle Dispose of waste water properly Check brake shoes replace if necessary See Section 6 in the DS Maintenance and Service Manual Brake System Lubricate brake slides per Lubrication Schedule See Section the DS Maintenance and Service Manual Semi annual Service by Trained Technician Only Every 50 hours of operation or 100 rounds of golf Check brake cables for damage replace as required Electrical wiring and connections Check for tightness and damage Check condition of wire connections Make sure Forward and Reverse F amp R Rocker Switch R connections tight Check and adjust as required See Section 7 in the DS Front Wheel Alignment and Camber Maintenance amp Service Manual Annual Service by Trained Technician Only Every 100 hours of operation or 200 rounds of golf A WARNING IF ANY PROBLEMS ARE FOUND DO NOT OPERATE THE VEHICLE UNTIL REPAIRS ARE MADE FAILURE TO MAKE NECESSARY REPAIRS COULD RESULT IN FIRE PROPERTY DAMAGE SEVERE PERSONAL INJURY OR DEATH If batteries are not performing as expected refer to Batteries Section 13 Batteries 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement 10 3 PERIODIC MAINTENANCE Lubrication LUBRICATION PERIODIC LUBRICATION SCHEDULE REGULAR INTERVAL SERVICE PLACE RE
118. er switch Remove and retain the screws lock washers and nuts attaching the limit switch to the wiper switch Disconnect the green white and blue wires from the limit switch Accelerator Pedal Limit Switch Installation 1 Position the Accelerator Pedal Limit switch on the wiper switch body and install the mounting screws lock washers and nuts Tighten the screws to 5 in lb 0 6 N m Connect the accelerator rod ball joint to the ball stud on the wiper switch Connect the green white wire to the normally closed NC terminal and the blue wire to the common COM terminal of the limit switch The normally open NO terminal should have no wire attached Install the cover on the wiper switch make sure all three tabs snap into place 5 Install and connect the No 5 and No 6 batteries leaving the No negative post disconnected Connect battery cables to battery No 1 positive first then connect cable to battery No negative Tighten ter minals to 110 in Ib 12 4 N m Place Tow Run switch in RUN Page 12 4 1998 1999 PowerDrive Plus Maintenance and Service Supplement ELECTRICAL COMPONENTS Reverse Buzzer REVERSE BUZZER Read DANGER and WARNING on page 12 1 Testing the Reverse Buzzer See Test Procedure 17 Section 11 Page 11 21 Reverse Buzzer Removal 1 Place Tow Run switch in the TOW position disconnect batteries Figure 12 1 Page 12 2 and discharge speed con troller 2 Remove center das
119. ers install the strain relief bushing and AC cord into the mounting hole in the charger face 5 Install the charger cover 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14 25 SECTION 15 MOTOR DANGER 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 ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL MECHANICAL AND ELECTRICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE PLACE THE TOW RUN SWITCH IN THE TOW POSITION BEFORE CONNECTING OR DISCONNECTING BATTERY WIRES BEFORE PERFORMING ANY TESTS OR REPAIRS THAT DO NOT REQUIRE THE ELECTRICAL SYS
120. gear assembly 4 Press new bearing 18 Figure 16 4 Page 16 4 or 16 Figure 16 5 Page 16 5 onto input pinion gear 5 Apply grease to the lip of the new oil seal 10 Figures 16 4 or 16 5 Pages 16 4 or 16 5 and install the seal using a transaxle pinion seal tool Club Car Part No 1014161 The lip of the oil seal should face the inside of the transaxle housing Make sure the seal is firmly seated Page 16 12 1998 1999 PowerDrive Plus Maintenance and Service Supplement TRANSAXLE Transaxle Disassembly Inspection and Assembly Transaxle Assembly Continued 6 Install the differential assembly the intermediate gear assembly and the input pinion gear simultaneously Be sure all bearings are seated properly in the housing Rotate the input shaft to check for smooth gear operation Figure 16 13 Page 16 9 7 Install both dowel pins 27 Figure 16 4 Page 16 4 or 25 Figure 16 5 Page 16 5 in transaxle housing 24 or 20 8 Install left half of transaxle housing For Type K transaxles 8 1 Place anew gasket 13 Figure 16 4 Page 16 4 in position on the mating face of the housing Use the dowel pins to position the gasket Make sure all holes are aligned 82 Install left half of transaxle housing 24 Figure 16 4 Page 16 4 8 3 Install the ten bolts 26 and tighten to 69 in Ib 7 8 N m Figure 16 4 Page 16 4 8 4 If the axle tube 16 and 40 was removed install the shims 39 if the shims were removed and a
121. generative braking when the batteries can accept a regenerative charge Turns the charger ON and OFF during the charge cycle Locks out the motor speed controller to prevent the vehicle from moving during the charge cycle Illuminates the dash warning light if there is a problem with the batteries Sends a signal from the dash light to the optional Communication Display Module FORWARD REVERSE SWITCH ONBOARD B sini COMPUTER CONNECTOR MAIN SOLENOID PIN 1 RED WIRE PIN 2 ORN WHT WIRE we PIN 6 YELLOW WIRE T RESISTOR 10 20 30 40 50 60 70 80 2 B 90100 110 120 139 140150 000 DYNAMIC Jj BRAKING SOLENOID PIN 13 GREEN WIRE Figure 11 4 Onboard Computer Circuit Page 11 6 1998 1999 PowerDrive Plus Maintenance and Service Supplement ELECTRICAL SYSTEM AND TESTING Electrical Circuits Battery Warning Light The dash light performs two functions for the vehicle s electrical system Warning Light The warning light alerts the operator to any problems with the batteries or charging system The warning light will illuminate under the following conditions 1 Battery no load voltage drops below 48 volts Batteries have discharged more than 75 of rated capacity AC power is interrupted during the charge cycle DC plug is still connected Charge cycle times out at 16 hours A W N When the DC cord is unplugged before the charge cycle is completed
122. ges 16 4 and 16 5 12 Install the retaining ring 6 Figures 16 4 and 16 5 Pages 16 4 and 16 5 in the axle tube See WARNING on page 16 6 13 Make sure the drain plug is installed in the transaxle and tightened to 23 ft lb 31 N m Fill the transaxle through the level indicator hole with 22 ounces of SAE 30 API Class SE SF or SG oil a higher grade may also be used Install and tighten the level indicator plug to 23 ft lb 31 N m 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement 16 13 TRANSAXLE Transaxle Installation SHIMMING THE TRANSAXLE Type K Transaxles Only If the differential case 36 and 33 transaxle housing 11 and 24 or axle tube 16 or 40 has been replaced the tran saxle may need new shims To determine whether new shims are necessary the transaxle must be completely assembled except for the short axle tube 16 and both axle shafts 1 and 2 Figure 16 4 Page 16 4 1 Stand the transaxle on end on the axle tube 2 Using a depth gauge measure the distance from the gasket seal surface of the axle tube gasket must be removed to the outer race of the bearing 14 on the differential case assembly 32 Figure 16 4 Page 16 4 See also Figure 16 21 Page 16 14 3 Use the following chart to determine whether shimming is required and if so how many shims Club Car Part No 1013781 should be used Distance from gasket seal surface to outer race or bearing INCHES MM
123. gressively more detailed and time consuming It is therefore suggested to begin with the first test and follow through with the other tests until the problem has been found as outlined in the Battery Trou bleshooting Chart Figure 13 7 Page 13 9 BATTERY CHARGER TEST The easiest way to monitor the condition of a vehicle s batteries is simply to observe the reading on the battery charger ammeter at the end of the charge cycle After a full charge disconnect the charger DC plug wait 20 to 30 seconds and reconnect the charger DC plug The ammeter needle will jump to 15 amps or more and then taper into the 5 to 8 amp range within 10 to 20 minutes indicating good fully charged batteries Continued poor performance may indicate a problem in the vehicle electrical system brakes or battery charger If the problem is not found in the vehicle or charging system proceed to the on charge voltage test Batteries that remain at 8 amps or higher should be tested further using the on charge voltage test ON CHARGE VOLTAGE TEST When the batteries are fully charged disconnect the charger DC plug Wait 20 to 30 seconds and reconnect the DC plug to restart the charger After 5 minutes use a multimeter to check and record the voltage of the battery set as well as the individual batteries Set the meter to 200 volts DC Place the red probe at the positive post of battery No 1 and the black probe at the negative post of battery No 6 Figure 13 5 Page 13
124. h See Remove Center Dash page 12 2 3 Disconnect the 18 gauge red and orange wires from reverse buzzer 4 Remove the two screws from the reverse buzzer Remove the reverse buzzer from the center dash panel Reverse Buzzer Installation 1 Install the reverse buzzer the reverse order of removal Tighten screws to 4 in lb 0 45 N m 2 Reconnect battery wires positive cable first and tighten to 110 in lb 12 4 N m Place Tow Run switch in the RUN position MAIN SOLENOID Read DANGER and WARNING on page 12 1 The main solenoid is located on the passenger side of the electrical component mounting plate Testing the Main Solenoid See Test Procedure 3 Section 11 Page 11 15 TYPICAL 2 PLACES W TYPICAL 2 PLACES Figure 12 4 Main Solenoid 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 12 5 ELECTRICAL COMPONENTS Dynamic Braking Solenoid Main Solenoid Removal 1 2 3 4 5 Place Tow Run switch in the TOW position and disconnect batteries See Figure 12 1 Page 12 2 Remove the rear body access door Disconnect all wires from the solenoid 12 Figure 12 4 Page 12 5 Loosen but do not remove one of the thread rolling screws 11 that hold the solenoid mounting bracket 10 to the component mounting plate Figure 12 4 Page 12 5 Lift the solenoid 12 up and out of the mounting bracket 10 Figure 12 4 Page 12 5 Main Solenoid Installation 1 2 3 4 5
125. he DC cord into the charger receptacle and plug the AC cord into an electrical outlet 13 Allow the charger to continue charging the batteries until the charger shuts off automatically 14 When the charge cycle is complete test the batteries again If the battery pack voltage is above 34 volts and the vehicle will not operate it will be necessary to troubleshoot the vehicle s electrical system to determine which electrical component has failed See Section 11 Electrical System and Testing 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 13 15 SECTION 14 POWERDRIVE BATTERY CHARGER A DANGER 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 AND RUBBER GLOVES WHEN WORKING ON 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 ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIR
126. he black wire of the DC cord 5 to the left as viewed from inside the charger post of the ammeter Figure 14 20 Page 14 23 Connect the bus bar 3 from the fuse link to the right post of the ammeter Place flat washers on both sides of the bus bar Figure 14 20 Page 14 23 Thread nuts onto both posts of the ammeter until just past finger tight While holding the outside nut turn the inside nut counterclockwise 1 4 turn Figure 14 20 Page 14 23 See following CAUTION Page 14 22 1998 1999 PowerDrive Plus Maintenance and Service Supplement POWERDRIVE BATTERY CHARGER Charger Repairs A CAUTION DO NOT ALLOW AMMETER POST TO ROTATE AS THE NUT 4 IS TIGHTENED IF IT IS ALLOWED TO ROTATE THE AMMETER COULD BE DAMAGED FIGURE 14 20 PAGE 14 23 6 Replace the charger cover Plug the charger into the vehicle and check ammeter for proper operation Figure 14 20 Ammeter Removal FUSE LINK Fuse Link Removal 1 Disconnect the AC and DC cords See WARNING on page 14 21 2 Remove the charger cover 3 Remove both black secondary transformer leads and the bus bar from the back of the fuse link assembly Fig ure 14 20 Page 14 23 4 Remove screws from the front of the charger and remove the fuse link assembly Fuse Link Installation 1 Place plastic cover over fuse assembly and install mounting screws from front of charger face The center branch of the fuse assembly should be in the upper left corner
127. ich indicates when CDM batteries are weak and need replacing Weak bat teries in the CDM may cause CDM to register inaccurate information or no information LOW BATTERY INDICATOR DISPLAY WINDOW COMMUNICATION di DISPLAY MODULE DISPLAY FUNCTIONS PRESS AND HOLD BUTTON TO SHOW FUNCTION NUMBER itid FUNCTION VALUE FUNCTION BUTTON Club Car COMMUNICATION DISPLAY MODULE Figure 11 14 CDM USING THE CDM TO RETRIEVE DATA FROM THE ONBOARD COMPUTER 1 Turn the CDM ON 2 Position CDM on seat bottom so it is aligned directly with the battery warning light Ensure CDM infrared LED receiver is pointed at battery warning light and there is a clear path between them See following NOTE NOTE IF BY POSITIONING CDM ON SEAT BOTTOM CDM IS UNABLE TO COLLECT DATA STREAM FROM OBC HOLD CDM APPROXIMATELY 6 IN FROM BATTERY WARNING LIGHT 3 Wait approximately 30 seconds for a value to appear in the display window 4 Ifa 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 from the same or another onbo
128. ing pin through differential gear case from one side Figures 16 4 or 16 5 Pages 16 4 or 16 5 See also Figure 16 19 Page 16 11 T EE DIFFERENTIAL PUSH DIFFERENTIAL DIFFERENTIAL PIN THROUGH GEAR DIFFERENTIAL 4 GEAR CASE Figure 16 19 Differential Pin Figure 16 20 Left Differential 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 16 11 TRANSAXLE Transaxle Disassembly Inspection and Assembly 9 6 Remove the idler gears and thrust plates 38 and 35 Figure 16 4 Page 16 4 or 29 and 28 Figure 16 5 Page 16 5 9 7 Remove the differential gears and thrust plates 34 and 37 Figure 16 4 Page 16 4 or 30 and 27 Fig ure 16 5 Page 16 5 See also Figure 16 20 Page 16 11 9 8 Inspect the bearings 14 Figure 16 4 Page 16 4 or 13 Figure 16 5 Page 16 5 of the differential case and replace them if they are damaged To remove them press them off See CAUTION at bottom of page 16 10 10 Inspect parts for wear or damage Any worn or damaged parts should be replaced See following NOTE NOTE e DAMAGED OR WORN GEARS SHOULD BE REPLACED AS SETS TRANSAXLE ASSEMBLY A CAUTION DO NOT PRESS AGAINST THE BEARING OUTER RACE TYPE TRANSAXLES GASKET 13 FACES OF THE HOUSING MUST BE CLEAN AND SMOOTH USE ONLY A NEW GASKET THAT IS NOT TORN OR DAMAGED THE GASKET MUST LIE FLAT AGAINST THE HOUSING FACES FIGURE 16 4 PAGE 16 4 THE HOUSING AND ALL PARTS MUST BE
129. ires Check continuity on A1 and A2 motor terminal posts and continuity of the F1 and F2 motor terminal posts Also check continuity of all motor wires See Section 15 Motor Test Procedure 6 Tow Run Switch 1 Using a multimeter set on 200 volts DC connect black lead to negative post of battery No 6 and connect red lead with insulation probe on black wire on two pin connector on Tow Run switch Connect the insulation probe to the black wire on the wire harness side of the two pin connector See WARNING on page 11 11 With the Tow Run switch in the RUN position the reading should be approximately 48 50 volts With the switch in the TOW position the reading should be zero volts Ifthe reading is not zero volts with the switch in the TOW position replace the switch 4 If the reading is zero volts with switch in the RUN position check continuity of the two pin connector and the red white 18 gauge wire from the large post of the solenoid to the two pin connector at the Tow Run switch Page 11 16 1998 1999 PowerDrive Plus Maintenance and Service Supplement ELECTRICAL SYSTEM AND TESTING Test Procedures 5 If the continuity readings are correct replace the Tow Run switch Test Procedure 7 Battery Pack Voltage Under Load 1 Before proceeding with this test procedure the batteries must be fully charged Using a 36 to 48 volt battery discharge machine Club Car No 101831901 connect the positive lead of the discharge m
130. l screw 25 and lock washer 14 through wiper arm into brush Tighten screw to 7 in Ib 0 8 N m Figure 12 13 Page 12 17 Install arm brush wire terminal 42 onto the bolt 29 and then install the nut 30 Thread the nut against the arm brush wire terminal and tighten it to 40 in lb 4 5 N m Figure 12 13 Page 12 17 Install the bolt 29 through the potentiometer housing 1 and then install the two nuts 30 onto the bolt Tighten the nuts to 40 in Ib 4 5 N m Figure 12 13 Page 12 17 Install the 18 gauge yellow wire onto the bolt 29 then install the lock washer 9 and nut 30 Tighten nut to 40 in Ib 4 5 N m Figure 12 13 Page 12 17 Connect the accelerator rod to the ball stud Check wiper arm brush contact for proper adjustment See Page 12 13 Check accelerator and brake pedal adjustment See Section 5 Accelerator and Brake Pedal Group in the Maintenance and Service Manual Page 12 14 1998 1999 PowerDrive Plus Maintenance and Service Supplement ELECTRICAL COMPONENTS Multi step Potentiometer 14 Install potentiometer cover and install and connect the No 5 and 6 batteries leaving the No negative post disconnected Tighten terminals to 110 in Ib 12 4 N m 15 Reconnect battery cables to battery No 1 positive first then connect cable to battery No 6 negative Tighten terminals to 110 in lb 12 4 N m Place the Tow Run switch in the RUN position MULTI STEP POTENTIOMETER ADJUS
131. l seal Insert the wedge bar underneath the seal lip and pry out oil seal Figure 16 3 Page 16 3 See following CAUTION Page 16 2 1998 1999 PowerDrive Plus Maintenance and Service Supplement TRANSAXLE Axle Shaft and Bearing Figure 16 1 Axle Tube Figure 16 2 Rolling Wedge Bar A CAUTION DO NOT SCAR OR DAMAGE THE INSIDE SURFACES OF THE TUBE WHEN REMOVING THE OIL SEAL A DAMAGED TUBE MIGHT HAVE TO BE REPLACED 6 Inspect the axle shaft assembly to be sure the bearing and collar have not slipped and are still seated against the shoulder on the axle shaft 7 Inspect bearing 5 Figure 16 4 Page 16 4 or Figure 16 5 Page 16 5 If the bearing in a Type K transaxle is worn or damaged replace bearing If the bearing in a Type G transaxle is worn or damaged see following NOTE at Axle Bearing Figure 16 3 Seal Lip 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 16 3 TRANSAXLE Axle Shaft and Bearing Page 16 4 1998 1999 PowerDrive Plus Maintenance and Service Supplement Axle Shaft and Bearing TRANSAXLE nd Service Supplement Page 16 5 1998 1999 PowerDrive Plus Vehicle Maintenance a TRANSAXLE Axle Shaft and Bearing AXLE BEARING NOTE DO NOT REMOVE AXLE BEARING FROM A G TRANSAXLE IF BEARING IS WORN OR DAMAGED THE ENTIRE AXLE ASSEMBLY 1 OR 2 MUST BE REPLACED FIGURE 16 5 PAGE 16 5 Axle Bearing
132. le insert the AC cord into an outlet The charger relay should NOT close A multimeter set to volts DC and connected across the DC plug positive and negative pins should indicate zero volts No transformer hum should be heard 2 Disconnect the AC cord from its outlet and connect the DC plug to the receptacle The charger relay should close with an audible click after a 2 to 15 second delay 3 If the charger does not operate as in steps 1 or 2 above refer to the wiring diagram Figure 14 4 Page 14 7 and make sure the charger is wired correctly Always monitor the first charge cycle to make sure the charger turns off properly If the DC cord is disconnected dur ing a charge and the batteries are less than 90 charged the battery warning light will illuminate intermittently See Battery Warning Light Page 14 3 Page 14 6 1998 1999 PowerDrive Plus Maintenance and Service Supplement POWERDRIVE BATTERY CHARGER Checking Battery Condition After A Charge Cycle CHECKING BATTERY CONDITION AFTER A CHARGE CYCLE Read DANGER and WARNING on page 14 1 It is common practice for technicians to check the condition of a set of batteries after they have charged to ensure they have received a complete charge before the vehicle is used With the PowerDrive Plus this practice is not neces sary The onboard computer controls and monitors the charge cycle If there is any problem during a charge cycle the battery warning light located above the s
133. ling the Motor Speed Sensor Page 15 14 1998 1999 PowerDrive Plus Maintenance and Service Supplement SECTION 16 TRANSAXLE DANGER 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 ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL AND MECHANICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE TURN KEY SWITCH OFF PLACE FORWARD REVERSE ROCKER SWITCH IN THE NEUTRAL POSITION AND REMOVE KEY BEFORE SERVICING THE VEHICLE MOVING PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CONNECTI
134. ltimeter set to 20 volts DC place the black lead on battery No 6 negative post and the red lead with insulation probe on the No 18 yellow wire at a point between the six pin connector and the wiper switch The reading should be approximately 3 75 volts with the pedal up Slowly depress the accelerator pedal and note the readings on the multimeter As the pedal is depressed the reading will decrease in increments until it reaches zero volts when the pedal is fully depressed 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement 11 15 ELECTRICAL SYSTEM AND TESTING Test Procedures Test Procedure 4 Multi step Potentiometer Wiper Switch Voltage Continued 6 7 If reading does not decrease as pedal is depressed check movable contact and resistors in wiper switch If the reading is not zero volts with the pedal fully depressed the vehicle will not operate at rated top speed Check the resistors and adjustment of the wiper switch assembly 7 1 Disconnect the six pin connector at multi step potentiometer 7 2 Using a multimeter set to 20K ohms connect black lead of multimeter to purple wire terminal end located in six pin connector on potentiometer Connect red lead with insulation probe to yellow wire at six pin connector 7 3 Measure resistance while depressing the accelerator pedal The measured resistance should increase incrementally in six steps 1st Step 910 ohms approx 2nd Step 1660
135. ly and Inspection 16 10 Transaxle Assembly 75 52 deca t det etai in e ER 16 12 Shimming the Transaxle detecte deor tei neat iae bay 16 14 Transaxte Installation 16 14 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page v Page vi 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement SECTION 10 PERIODIC MAINTENANCE A WARNING IF ANY PROBLEMS ARE FOUND DURING SCHEDULED INSPECTION OR SERVICE DO NOT OPERATE THE VEHICLE UNTIL REPAIRS ARE MADE FAILURE TO MAKE NECESSARY REPAIRS COULD RESULT IN FIRE PROPERTY DAMAGE SEVERE PERSONAL INJURY OR DEATH ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL AND MECHANICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL TURN KEY SWITCH OFF PLACE FORWARD REVERSE ROCKER SWITCH IN THE NEUTRAL POSITION AND REMOVE KEY PRIOR TO SERVICING MOVING PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING HOT DO NOT ATTEMPT TO SERVICE HOT MOTOR OR RESISTORS FAILURE TO HEED THIS WARNING COULD RESULT IN S
136. m controller B terminal Figure 12 6 Page 12 8 Disconnect the gray wire fuse holder at the charger receptacle Disconnect the black 10 gauge wire 8 at the charger receptacle Cut the wire tie that secures the OBC wire harness to the I beam Loosen do not remove self tapping screws 17 holding OBC to component mounting plate Figure 12 6 Page 12 8 Slide OBC towards outside of vehicle and align heads of self tapping screws 17 with the two holes in the OBC face plate Figure 12 6 Page 12 8 Pull OBC towards rear of vehicle and remove from component mounting plate Onboard Computer Installation 1 2 3 Place Tow Run switch in the TOW position and disconnect the batteries Figure 12 1 Page 12 2 Remove the rear body access door Install OBC onto component mounting plate by aligning two holes on OBC face plate with two holes on component mounting plate Slide OBC towards inside of vehicle and align heads of self tapping screws 17 with smaller part of two holes in OBC face plate Figure 12 6 Page 12 8 Tighten screws to 60 in Ib 6 7 N m 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 12 7 ELECTRICAL COMPONENTS Onboard Computer OBC Onboard Computer Installation Continued TYPICAL 2 PLACES Figure 12 6 Onboard Computer Attach wire tie so the OBC wire harness is secured to the I beam Connect the black 10 gauge wire 8 to the charger receptacle Connect th
137. mounting tabs and remove coil Figure 12 5 Page 12 6 Energy Displacement Module Installation 1 Installation is reverse of removal Position the coil ends as shown in Figure 12 5 Page 12 6 and tighten the nuts 6 to 75 in lb 8 5 N m See also Figure 12 14 Page 12 18 See following CAUTION A CAUTION BE SURE ALL WIRES ARE SECURED IN PLACE SO THEY DO NOT COME INTO CONTACT WITH THE COIL 2 Reconnect battery cables positive cable first and tighten to 110 in Ib 12 4 N m Place the Tow Run switch in the RUN position J DYNAMIC BRAKIN SOLENOID RESISTOR COILS Figure 12 14 Energy Displacement Module Page 12 18 1998 1999 PowerDrive Plus Maintenance and Service Supplement ELECTRICAL COMPONENTS Tow Run Switch Figure 12 15 Tow Run Switch TOW RUN SWITCH Read DANGER and WARNING on page 12 1 Testing the Tow Run Switch See Section 11 Test Procedure 6 Page 11 16 Tow Run Switch Removal 1 Place Tow Run switch in TOW and disconnect the battery wires as shown Figure 12 1 Page 12 2 Remove Tow Run switch boot hex nut 6 Figure 12 15 Page 12 19 Remove nut 9 and Tow Run switch 10 from bracket 5 Figure 12 15 Page 12 19 Disconnect two pin connector 11 and remove switch Figure 12 15 Page 12 19 WN Tow Run Switch Installation 1 Installation is reverse of removal Make sure groove on switch is aligned with tang on bracket If knurled nut is present tighte
138. n 1 Install the 910 ohm resistor assembly 26 color bands white brown and gold onto the third and fourth threaded posts Figure 12 12 Page 12 16 See following NOTE NOTE THE COLOR BANDS ON THE RESISTORS DO NOT NEED TO BE ORIENTED IN ANY PARTICULAR DIRECTION WHEN INSTALLED 2 Install the 750 ohm resistor assembly 27 color bands violet green brown and gold onto the fourth and fifth threaded posts Figure 12 12 Page 12 16 3 Install the 910 ohm resistor assembly 28 color bands white brown and gold onto the fifth and sixth threaded posts Figure 12 12 Page 12 16 4 Install the 1000 ohm resistor assembly 29 color bands brown black red and gold onto the sixth and sev enth threaded posts Figure 12 12 Page 12 16 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 12 15 ELECTRICAL COMPONENTS Battery Warning Light Resistor Installation Continued Figure 12 12 Resistors 5 Install the 1000 ohm resistor assembly 30 color bands brown black red and gold onto the seventh and eighth threaded posts Figure 12 12 Page 12 16 6 Install the 1000 ohm resistor assembly 31 color bands brown black red and gold onto the eighth and ninth threaded posts Figure 12 12 Page 12 16 7 Make sure the purple wire 24 is connected to the third threaded post and the white black wire 25 is con nected to the ninth threaded post Figure 12 12 Page 12 16
139. n nut 9 to 23 in Ib 2 6 N m Tighten Tow Run switch boot hex nut 6 to 16 in lb 1 8 N m Figure 12 15 Page 12 19 2 Reconnect battery wires positive cable first and tighten to 110 in Ib 12 4 N m Coat terminals with Battery Protector Spray Club Car Part No 1014305 to minimize corrosion 3 Place Tow Run switch in the RUN position 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement 12 19 SECTION 13 BATTERIES DANGER 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 AND RUBBER GLOVES WHEN WORKING ON 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 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 WARNINGS STATED IN THIS MANUAL ALWAYS WEAR APPRO
140. n 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 te
141. n the six pin connector located at the OBC If the continuity of the orange white wire to the blue OBC wire in the six pin connector is present replace the dynamic braking solenoid Test Procedure 9 Key Switch and Limit Switch Circuit 1 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 the wiper switch six pin connector harness side See WARNING on page 11 11 2 With Tow Run switch in RUN key switch ON and Forward Reverse rocker switch in FORWARD the voltage reading should be zero volts When the accelerator pedal is depressed the voltage reading should be approx 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 11 17 ELECTRICAL SYSTEM AND TESTING Test Procedures 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 23 If the r
142. nal retaining nuts to 65 in Ib 7 3 N m See following NOTE NOTE THE MOTOR WIRES SHOULD HAVE BEEN TAGGED FOR IDENTIFICATION WHEN THEY WERE DISCONNECTED IF THE WIRES WERE NOT TAGGED SEE WIRING DIAGRAM IN SECTION 11 FIGURE 11 1 PAGE 11 2 7 If using a chain hoist lower the vehicle and guide the leaf springs into the shackles If using a floor jack raise the transaxle until the leaf springs can be guided into the shackles 8 Insert mounting bolts through spring shackles and bushings in leaf spring eyes and install lock nuts Tighten bolts to 23 ft lb 31 N m See Section 9 Rear Suspension the Maintenance and Service Manual 9 Install the shock absorbers Tighten nut until rubber bushing expands to the size of the cup washer 10 If removed reinstall wheels See Section 8 Wheels and Tires in the Maintenance and Service Manual Tighten lug nuts to 55 ft lb 74 6 N m 11 Connect the battery cables positive cable first Tighten cables to 110 in lb 12 4 N m Figure 15 1 Page 15 2 Coat terminals with Batter Protector Spray Club Car Part No 1014305 to minimize corrosion Place Tow switch in the RUN position MOTOR SPEED SENSOR Read DANGER and WARNING on page 15 1 Testing the Motor Speed Sensor See Test Procedure 14 Section 11 Page 11 19 Page 15 12 1998 1999 PowerDrive Plus Maintenance and Service Supplement Motor Speed Sensor END SHIELD MOUNTING SCREW RIGGING BEARING RETAINER
143. nected to the left side of the ammeter when viewed from inside the charger If a reverse polarity connection is made between the charger and the batteries both fuse links will blow when the DC cord is plugged into the vehicle whether or not the AC cord is plugged into an outlet 3 On rare occasions both diodes may fail as the result of a lightning strike at the charging location 4 Excessive heat due to a loose connection may also cause both fuse links to melt Be sure fuse connections are tightened to 20 in lb 2 2 N m 5 Besure the charger is wired properly and all connections are clean and tight DISCONNECT SECONDARY COIL LEAD Figure 14 12 Diode Test Figure 14 13 Diode Test Reverse Probe Position 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14 15 POWERDRIVE BATTERY CHARGER Test Procedures Test Procedure 5 Charger DC Circuit Continuity Test 1 Using a continuity tester Club Car Part No 1011273 or multimeter set to 200 ohms connect the test leads to the pins marked and on the DC plug Figure 14 14 Page 14 16 and note the readings 2 Reverse the test leads and check the DC plug again Figure 14 15 Page 14 16 The circuit should show con tinuity in only one direction 3 If the circuit does not show continuity in either direction and the charger fuse is not blown individually check the continuity of the DC plug and cord Test Procedure 8 ammeter Test Proc
144. ohms approx 3rd Step 2570 ohms approx Ath Step 3570 ohms approx 5th Step 4570 ohms approx 6th Step 5570 ohms approx NOTE 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 SPEED SWITCH RESISTOR ASSEMBLY IS IN GOOD CONDITION 8 74 Ifthe resistance steps were not correct and the accelerator pedal is properly adjusted then replace the defective resistor s See Section 12 Components 7 5 Reconnect six pin connector assembly If reading is zero volts check continuity of yellow wire and six pin connector terminal at wiper switch Test Procedure 5 A1 and A2 Motor Voltage 1 Using a multimeter set to 200 volts DC place the black lead on the A2 motor terminal white wire and con nect the red lead to the A1 green wire motor terminal See DANGER on page 11 11 With Tow Run switch in RUN place Forward Reverse switch in FORWARD turn key switch ON and slowly depress accelerator pedal As the accelerator pedal is depressed the voltage reading should increase from approximately 5 volts when the accelerator limit switch closes to approximately 48 volts with the accelerator pedal fully depressed 3 1 If there is no voltage reading check the wiper switch see Test Procedure 4 and the continuity of the large post of the main solenoid see Test Procedure 15 3 2 Disconnect battery w
145. one in the morning Reality Under most circumstances water should be added after charging See Battery Care Page 13 5 Underwatering Misconception Checking the water takes too much time it can be checked once a month Reality Insufficient watering can ruin batteries Water level should be checked weekly See Battery Care Page 13 5 Vibration Damage Misconception You should tighten battery hold downs as tight as you Reality Battery hold downs should be tightened to specification Hold downs that are too tight or too loose can cause battery damage See Battery Care Page 13 5 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement 13 3 BATTERIES Replacing Batteries REPLACING BATTERIES Read DANGER and WARNING on page 13 1 A WARNING TO PREVENT ELECTROLYTE LEAKAGE FROM THE BATTERY VENTS BATTERIES MUST BE KEPT IN AN UPRIGHT POSITION TIPPING A BATTERY BEYOND A 45 ANGLE IN ANY DIRECTION CAN ALLOW A SMALL AMOUNT OF ELECTROLYTE TO LEAK OUT THE VENT HOLE DO NOT EXCEED THIS 45 ANGLE WHEN LIFTING CARRYING OR INSTALLING BATTERIES BATTERY ACID CAN CAUSE SEVERE PERSONAL INJURY TO SKIN OR EYES AND CAN DAMAGE CLOTHING 1 Before removing batteries note the orientation of the batteries and the connecting wires First place the Tow Run switch in the TOW position Disconnect the batteries and discharge the controller as described in the WARNING on page 13 1 Then remo
146. onnect the No 5 and No 6 batteries leaving the No 6 negative post disconnected Tighten terminals to 110 in lb 12 4 N m 10 Reconnect battery cables to battery No 1 positive 4 first then connect cable to battery No 6 negative Tighten terminals to 110 in lb 12 4 N m Place the Tow Run switch in the RUN position 11 Drive the vehicle and inspect it for proper operation A CAUTION DO NOT OPERATE VEHICLE WITHOUT WIPER SWITCH COVER IN PLACE OPERATING THE VEHICLE WITHOUT THE COVER ALLOWS DIRT DUST AND WATER TO CONTAMINATE THE WIPER SWITCH WHICH COULD CAUSE THE SWITCH TO FAIL OR MALFUNCTION MULTI STEP POTENTIOMETER ARM ADJUSTMENT The contact surfaces on the multi step potentiometer arm brush and fixed contacts must be parallel to ensure efficient operation of the multi step potentiometer Figure 12 10 Page 12 14 Adjust arm contact as follows 1 Place Tow Run switch in the TOW position and disconnect battery cables negative cable first Figure 12 1 Page 12 2 Remove the No 5 and No 6 batteries from the vehicle and remove the cover from the multi step potentiometer 2 Test the multi step potentiometer arm and fixed contacts for proper adjustment 21 With a dry erase marker completely coat each of the fixed contacts 2 2 Sweepthe multi step potentiometer arm brush back and forth across the fixed contacts Scraping of the ink should show contact on at least 3096 of the surface on each fixed contact
147. ontrol Cres A add Uode eae Sees Rue A ee ei a II 11 4 The Power Circuit cito eee Penne Shes oe e C 11 7 11 10 The c 11 10 Index of Test Procedures nnne nnns 11 11 Diagnostic Flow 11 11 Test Procedures oc aito let apad vibe 11 14 The Communication Display Module CDM seem enn 11 22 Using The To Retrieve Data From The Onboard Computer sse 11 23 CDM Troubleshooting Guide ener enne seen nennen nnn nennen 11 24 SECTION 12 ELECTRICAL COMPONENTS Kay SWITCH Ps e Ot 12 2 Forward Reverse F amp R Rocker Switch nennen nnne nennen 12 3 Accelerator Pedal has Het ido rp Potente le de iu aei hated 12 4 Reverse BUZZER tiet ode De b HERR M Leere iud tu et ma eot iuh 12 5 Main S lenoig MD 12 5 Dynamic Braking SOlGNOIG eei r teo AEE 12 6 Onboard Computer OBC aE eri ARa EEA 12 7 Solid State Speed Controller 12 9 Charger Receptacle Assembl
148. oted throughout this section LUBRICATION There are two plugs located on the lower half of the transaxle housing The upper plug as viewed when the vehicle is ona level surface is used as a lubricant level indicator When the vehicle is parked on a level surface the lubricant level should be even with the bottom of the hole The lower plug is for draining the lubricant When draining the lubricant the upper plug should be removed so the lubricant will drain faster Be sure the drain plug is reinstalled before refilling NOTE e RECYCLE OR DISPOSE OF USED OIL OR LUBRICANT IN ACCORDANCE WITH LOCAL STATE AND FEDERAL REGULATIONS AXLE SHAFT AND BEARING Read DANGER and WARNING on page 16 1 AXLE SHAFT Axle Shaft and Oil Seal Removal 1 Place chocks at the front wheels Loosen lug nuts on rear wheels and lift the rear of the vehicle with a chain hoist or floor jack Place jackstands under the axle tubes to support the vehicle 2 Remove the rear wheel and brake drum See Section 6 Wheel Brake Assemblies and Section 8 Wheels and Tires in the Maintenance and Service Manual 3 Using 90 internal snap ring pliers remove the internal retaining ring 6 from the axle tube Figures 16 4 or 16 5 Pages 16 4 or 16 5 See also Figure 16 1 Page 16 3 4 Remove the axle retaining ring and bearing assembly by pulling the axle straight out of thehousing 5 Use a 16 in 40 cm rolling wedge bar Figure 16 2 Page 16 3 to remove oi
149. ould be approximately 48 volts 4 3 If the reading is zero volts replace the OBC 5 Ifthe dash light does not illuminate and the solenoids do not click check the OBC activation circuit 5 1 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 red 18 gauge wire with the yellow fuse holder located on the OBC side of the fuse holder The reading should be approximately 48 volts 5 2 Ifreading is zero volts test fuse and fuse holder located in red 18 gauge wire Using a multimeter set to 200 34 connect red lead to one end of fuse and connect black lead to other end of fuse Multime ter should indicate continuity 5 3 Place wire probe on the 18 gauge red white wire harness side of six pin connector Multimeter should indicate 48 volts If voltage is correct check connections in the six pin connector If connections are cor rect OBC activation circuit has failed Replace OBC Test Procedure 3 Voltage At Main Solenoid Activating Coil 1 Place Tow Run switch in TOW and wait 10 seconds before proceeding See WARNING on page 11 11 Using a multimeter set to 200 volts DC place black lead on small post with blue white wire and place red lead on small post with blue wire 2 Place Tow Run switch in RUN Solenoid should activate for 2 3 seconds and then deactivate When solenoid clicks voltage reading should be approximately 48 volts full
150. pin connector 2 from the wire harness at the multi step potentiometer Figure 12 9 Page 12 12 6 Remove the nuts 6 and washers 7 from underneath the and lift the multi step potentiometer assembly from the frame Remove the shim plate 8 Figure 12 9 Page 12 12 Multi step Potentiometer Disassembly 1 Remove nuts 30 and slide bolt 29 out of potentiometer housing Figure 12 13 Page 12 17 2 Remove the nut 32 and bell crank 34 Figure 12 13 Page 12 17 3 Slide the wiper arm assembly out of the housing 1 Figure 12 13 Page 12 17 4 Remove the spring cotter pin if present 18 and disassemble the wiper arm assembly Unscrew the adjust ment screw 23 retainer nut 19 and spring 21 Remove all thread locking compound if present from the threads using gasket remover Figure 12 13 Page 12 17 5 To remove the bearings 22 Figure 12 13 Page 12 17 lightly tap them from the back with a punch Multi step Potentiometer Assembly 1 Install bearings 22 into the potentiometer housing by lightly tapping them with a plastic hammer Make sure the collars of the bearings are flush against the housing Figure 12 13 Page 12 17 2 With spring 21 in place hold wiper arm 26 and carrier 20 together Figure 12 13 Page 12 17 See following CAUTION A CAUTION e MAKE SURE THE SPRING IS IN THE RECESSED AREA OF THE WIPER ARM IF THE SPRING IS NOT IN PLACE THE WIPER ARM MAY BREAK IF FORCED
151. power to the OBC and controller is shut off disabling the vehicle operating circuit and zero speed detect allowing the vehicle to be towed Motor Protection Circuit If the vehicle is held in position on an incline by partially depressing the accelerator pedal instead of the brake motor overheating could result The motor protection circuit reduces the possibility of motor damage during this circumstance High Pedal Detect This function prevents unexpected vehicle movement if the key switch is turned ON after the accelerator is depressed The vehicle will not move until the accelerator is depressed again Onboard Computer OBC The OBC 1 monitors battery condition 2 monitors the rate of discharge while the vehicle is in use 3 determines the amount of charge required based on the amount of use and shuts the charger off when this number is reached 4 determines when to activate regenerative motor braking 5 stores operating data which can be read by the Communication Display Module CDM and 6 locks out vehicle movement while the charger is plugged in ELECTRICAL CIRCUITS Read DANGER and WARNING on page 11 1 The PowerDrive Plus vehicle has three distinct circuits 1 the Control Circuit Figure 11 5 Page 11 8 2 the Power Circuit Figure 11 7 Page 11 9 and 3 the Charge Circuit Figure 11 8 Page 11 10 THE CONTROL CIRCUIT The Control Circuit consists of three individual circuits 1 Onboard Computer Circuit Figure 11 4 P
152. pping screws 11 that hold the solenoid mounting bracket 10 5 to the component mounting plate Figure 12 5 Page 12 6 Lift the solenoid 12 up and out of the mounting bracket 10 Figure 12 5 Page 12 6 Dynamic Braking Solenoid Installation 1 Mount solenoid onto component mounting plate with mounting bracket 10 Figure 12 5 Page 12 6 2 Tighten thread rolling screws 11 to 60 in Ib 6 7 N m Figure 12 5 Page 12 6 3 Install washers 8 mounting tabs 2 wires 13 14 and flanged lock nuts 1 onto large mounting posts Tighten nuts to 60 in lb 6 7 N m Figure 12 5 Page 12 6 See Section 11 Figure 11 1 Page 11 2 for correct wire desti nations 4 Install wires 15 16 and nuts 7 onto small mounting posts Tighten nuts to 18 in lb 2 0 N m Figure 12 5 Page 12 6 5 Install rear body access door 6 Connect batteries positive cable first and tighten to 110 in lb 12 4 N m Figure 12 1 Page 12 2 Place Tow Run switch in RUN ONBOARD COMPUTER OBC Read DANGER and WARNING on page 12 1 Testing the Onboard Computer See Test Procedures 2 11 and 12 Section 11 Page 11 14 Page 11 18 and Page 11 19 Onboard Computer Removal Place Tow Run switch in the TOW position and disconnect the batteries Figure 12 1 Page 12 2 Remove rear body access door and unplug six pin connector 16 at OBC Figure 12 6 Page 12 8 Remove black 10 gauge and 6 gauge wires 9 and 14 fro
153. pr 1998 1999 Maintenance and Service Manual Supplement PowerDrive Plus Vehicles Manual Number 101968405 Edition Code 0299C1208B FOREWORD The Club Car PowerDrive Plus electric vehicle is engineered and built to provide the ultimate in performance efficiency However timely and appropriate vehicle maintenance and repair is essential for long term vehicle performance and continued safe and reliable service This supplement provides detailed information for the maintenance and repair of PowerDrive Plus electric vehicles and should be used in conjunction with the 1998 1999 DS Golf Car Maintenance and Service Man ual Publication Part No 101968401 If you do not have the 1998 1999 DS Golf Car Maintenance and Service Manual you may order one from your local Club Car representative This supplement and the 1998 1999 DS Golf Car Maintenance and Service Manual should be thoroughly reviewed prior to servicing the vehicle The procedures provided herein must be properly implemented and the CAUTION WARNING and DANGER statements must be heeded This supplement was written for the vehicle technician who already possesses basic knowledge and skills in electrical and mechanical repair f the technician does not have such basic knowledge and skills attempted service or repairs to the vehicle may render the vehicle unsafe For this reason Club Car advises all repairs and or service be performed by an authorized Club Car distributor dealer repre
154. r Figure 14 16 Page 14 17 4 Be sure secondary coil leads not touching one another With relay bypassed insert AC plug into an outlet If AC line fuse or circuit breaker blows the transformer is shorted internally and must be replaced 5 If the AC line fuse or circuit breaker does not blow check the transformer secondary voltage across lead Nos 1 and 5 using a multimeter set to 500 volts AC If measured voltages are approximately 85 volts AC or lower for the secondary coil the transformer is shorted internally and must be replaced Figure 14 16 Page 14 17 See following DANGER Page 14 16 1998 1999 PowerDrive Plus Maintenance and Service Supplement POWERDRIVE BATTERY CHARGER Test Procedures DANGER DO NOT ALLOW SECONDARY COIL LEADS TO TOUCH ONE ANOTHER THERE ARE APPROXIMATELY 120 VOLTS PRESENT 6 If the transformer output measurements are 86 volts AC or higher disconnect the AC plug from its outlet 7 If the voltage readings are normal the transformer is good Refer to Test Procedure 5 for further tests of the DC circuit DC CORDSET HEAT SINK ASSEMBLY 15 AMP AC CIRCUIT I BREAKER 9 SECONDARY BLACK COIL PRIMARY COIL EN USE ASSv AMMETER TRANSFORMER AC CORDSET Figure 14 16 Transformer Test Wiring Diagram Test Procedure 7 Battery State of Charge 1 After the charger has shut off disconnect the DC charger plug for approximately 20 seconds
155. re 14 9 Receptacle Wire Connections Figure 14 10 Battery Pack 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14 13 POWERDRIVE BATTERY CHARGER Test Procedures Figure 14 11 Test AC Cord Test Procedure 3 AC Power and Continuity Check of AC Circuit gt V Disconnect the AC power supply cord from its outlet and the DC plug from the vehicle receptacle Check the AC circuit breaker on the front of the charger and reset it if necessary Check the AC line fuse or circuit breaker in the storage facility With a multimeter set at 500 volts AC check incoming AC voltage Insert blades into outlet voltage should be 105 to 128 volts If proper voltage is not present have building wiring checked by a licensed electrical con tractor Remove charger cover and check continuity of the AC circuit 5 1 Disconnect the tan lead from the primary coil and the black lead from the circuit breaker from the charger relay Connect the tan lead to the circuit breaker Figure 14 16 Page 14 17 5 With relay bypassed there should be continuity across AC cord blades Figure 14 11 Page 14 14 If the circuit is not complete check the wiring of the AC cord transformer primary coil leads internal AC cir cuit breaker and jumper wire Figure 14 16 Page 14 17 If the charger is wired correctly check the continuity of the AC cord transformer primary coil and the jumper wire individually Test Procedure 8
156. rmation Controls in the 1998 1999 DS Maintenance and Service Manual Page 10 2 1998 1999 PowerDrive Plus Maintenance and Service Supplement PERIODIC MAINTENANCE Periodic Service Schedule PERIODIC SERVICE SCHEDULE A WARNING e SERVICE REPAIRS AND ADJUSTMENTS MUST BE MADE PER INSTRUCTIONS IN THE 1998 1999 DS GOLF CAR MAINTENANCE amp SERVICE MANUAL AND THIS SUPPLEMENT NOTE e IF THE VEHICLE IS CONSTANTLY SUBJECTED TO HEAVY USE OR SEVERE OPERATING CONDITIONS THE PREVENTATIVE MAINTENANCE PROCEDURE SHOULD BE PERFORMED MORE OFTEN THAN RECOMMENDED IN THE SERVICE AND LUBRICATION SCHEDULES BOTH THE PERIODIC SERVICE SCHEDULE AND PERIODIC LUBRICATION SCHEDULE MUST BE FOLLOWED TO KEEP VEHICLE IN OPTIMUM OPERATING CONDITION PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Daily Service by Owner Batteries Charge batteries after each use only Weekly Service by Owner Bares Check electrolyte level Add water as necessary per Section 13 Batteries Wash battery tops and clean terminals with baking soda Batteries water solution Dispose of waste water properly Tires Check air pressure and adjust as necessary Monthly Service by Owner or See Vehicle Capacities Chart on Page 10 4 Trained Technician Check for cracks or other damage make sure switch is securely fastened to frame Check movable contact for correct operation Multi step Potentiometer Wash battery compartm
157. rminal 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 ELECTRICAL SYSTEM AND TESTING Test Procedures Test Procedure 17 Reverse Buzzer 1 If the vehicle will not move and the solenoids do not click place the Forward Reverse rocker switch the REVERSE position and listen for the reverse warning buzzer to sound See WARNING on page 11 11 1 1 If the buzzer sounds it is an indication that the Tow Run switch and the OBC are operating properly and sending a voltage signal to the other components in the electrical system Test the voltage at the main solenoid activating coil See Test Procedure 3 1 2 If the buzzer does not sound the OBC or controller may be defective and should be tested See Test Procedure 2 See also following NOTE NOTE THE BUZZER WILL NOT SOUND IF IT HAS FAILED USE THE FOLLOWING PROCEDURE TO TEST THE BUZZER 2 Place Tow switch in the TOW position and disconnect the battery wires negative cable first 3 Remove the center
158. rpreting Discharge Test Results 1 If discharge time is 60 minutes or higher the problem is not with the batteries 2 If discharge times are low compare individual battery voltages recorded in step 5 If any battery shows a 0 4 volt or greater variance the battery is defective or nearing the end of its useful life and should be discarded or grouped with other batteries at or around same voltage The voltage of a defective battery will drop more rapidly near the end of the discharge than that of a sound battery BATTERY VOLTAGES BATTERY CONDITION 7 00 7 00 7 00 7 00 7 00 7 00 EXCELLENT 7 07 7 07 7 22 6 50 7 07 7 07 BATTERY 41S NEAR END OF USEFUL LIFE 7 20 7 20 6 67 7 33 6 27 7 33 BATTERY NOS 3 AND 5 ARE NEAR END OF USEFUL LIFE 3 If all the batteries are within 0 30 volts of each other but the discharge time is low the batteries are approaching the end of their life and the whole set will have to be replaced In general vehicles that discharge in less than 60 minutes at 78 F on the discharge test will typically not hold a charge for an entire work shift However discharge time is dependent on the electrolyte temperature The table shown gives the discharge times at various tempera tures of a set of batteries that delivers 62 minutes at 80 F ELECTROLYTE DISCHARGE TIME TO ELECTROLYTE DISCHARGE TIME TO TEMP F SHUT OFF POINT TEMP F SHUT OFF POINT 40 Minutes 85 89 64 Minutes 45
159. rtens the life of the battery It may also cause acid to leak out of the vent caps and corrosion to build up on surrounding metal parts The acid which is lost reduces the capacity of the battery and cannot be replaced Battery hold downs should NOT be so tight as to crack or buckle the battery case This may cause leaks which would dry up a cell or cause internal shorts See Replacing Batteries Page 13 4 BATTERY CHARGING Read DANGER and WARNING on page 13 1 GENERAL INFORMATION The charger supplied with the PowerDrive Plus electric vehicle resolves the most common problems associated with battery charging Undercharging and overcharging are prevented provided the charger is allowed to shut off Page 13 6 1998 1999 PowerDrive Plus Maintenance and Service Supplement BATTERIES Battery Charging by itself Also all cells are automatically given an equalization charge at low current which prolongs battery life Bat teries should never be left in a discharged state as this too affects the internal components and can reduce the capacity of the battery The batteries should be charged every day they are used However the batteries should not be charged if they have not been used CHARGER SHUTS OFF AFTER 16 HOURS This may be due to 1 new batteries 2 hard use or 3 cold temperatures A catch up charge may be necessary when these conditions are present On those days when all or some of the vehicles do not get used check the batteries for st
160. sentative or by a Club Car fac tory trained technician This service supplement along with the appropriate Maintenance and Service Manual covers all aspects of typical service requirements for the PowerDrive Plus electric vehicle If you need additional information you may write to us at Club Car Inc PO Box 204658 Augusta GA 30917 or contact a Club Car technical ser vice representative at 706 863 3000 ext 3580 1999 Club Car Inc Club Car PowerDrive PowerDrive Plus are registered trademarks of Club Car Inc This manual effective August 18 1997 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page i A WARNING e READ SECTION 1 IN THE MAINTENANCE AND SERVICE MANUAL BEFORE ATTEMPTING ANY SERVICE ON THIS VEHICLE e BEFORE SERVICING VEHICLE READ COMPLETE SECTION S AND ANY REFERENCED INFORMATION RELEVANT TO SERVICE OR REPAIR TO BE PERFORMED NOTE THIS MANUAL REPRESENTS THE MOST CURRENT INFORMATION AT THE TIME OF PUBLICATION CLUB CAR INC IS CONTINUALLY WORKING TO FURTHER IMPROVE OUR VEHICLES AND OTHER PRODUCTS THESE IMPROVEMENTS MAY AFFECT SERVICING PROCEDURES ANY MODIFICATION AND OR SIGNIFICANT CHANGE IN SPECIFICATIONS OR PROCEDURES WILL BE FORWARDED TO ALL CLUB CAR DISTRIBUTORS AND DEALERS AND WILL WHEN APPLICABLE APPEAR IN FUTURE EDITIONS OF THIS MANUAL DAMAGE TO A VEHICLE OR COMPONENT THEREOF NOT RESULTING FROM A DEFECT OR WHICH OCCURS DUE TO UNREASONABLE OR UN
161. smooth with 400 grit or finer sandpaper See following CAUTION and NOTE 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 15 5 Testing and Inspecting Individual Components A CAUTION e NEVER USE EMERY CLOTH TO SMOOTH THE COMMUTATOR PARTICLES OF EMERY ARE CONDUCTIVE AND MAY SHORT CIRCUIT THE COMMUTATOR BARS NEVER USE OIL OR LUBRICANTS ON THE COMMUTATOR OR BRUSHES NOTE OIL ON THE COMMUTATOR MAY INDICATE A FAULTY TRANSAXLE INPUT SHAFT OIL SEAL Armature Ground Test A CAUTION DO NOT SUBMERGE THE ARMATURE IN SOLVENT NOTE e BEFORE TESTING THE ARMATURE WIPE IT CLEAN WITH A CLEAN CLOTH REMOVE ANY CARBON DUST AND METAL PARTICLES FROM BETWEEN THE COMMUTATOR BARS 1 With a multimeter set to 200 ohms place one probe on the commutator and the other on the armature core The multimeter should indicate no continuity Figure 15 7 Page 15 6 If the reading is incorrect replace the motor K Figure 15 7 Armature FIELD WINDINGS Burned or scorched insulation on the field windings indicates the motor has overheated due to overloads or grounded or shorted coil windings If the insulation on the field windings is scorched replace the motor or the sta tor shell assembly Page 15 6 1998 1999 PowerDrive Plus Maintenance and Service Supplement MOTOR Testing and Inspecting Individual Components Figure 15 8 Motor 1998 1999 Po
162. sting 15 2 MOO a 15 3 Testing and Inspecting Individual Components 15 5 2 iin hee irr bebe 15 5 Field Windings 15 6 Motor 5 15 8 Bearing Inspection ice ete 15 8 Bearing Removals cde eatin dh dee deb ede 15 8 Guide RING INSPECTION 2 15 8 Reconditioning the Motor A hehe Eo aad 15 9 Motor Assembly xia tee Rd 15 10 Motor Installation eom Hep e cette ies eredi 15 12 Motor Speed Sensor aimed dat conan dat Rs a E qux RC 15 12 SECTION 16 TRANSAXLE General Information trt pt e Her i RUP P e Es 16 2 L bricati n m EE 16 2 Axle Shatt and Bearing o ede 16 2 Axle Shaft Mot eate 16 2 Axle Bearrg eta Re RA ERE 16 6 CI 16 8 Transaxle Reroval t lebe gilt eddies an 16 8 Transaxle Disassembly Inspection and Assembly 16 10 Transaxle Disassemb
163. t 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
164. t is controlled by the PowerDrive Plus onboard computer When the batteries receive an incomplete charge because 1 the DC power cord is disconnected 2 AC power to the charger is interrupted 3 automatic charger shut off occurs after 16 hours of operation or 4 the charger malfunc tions the warning light will indicate as follows The warning light will not illuminate if the charge is 90 or more complete The onboard computer will retain in memory the amount of charge needed to fully replenish the batteries and will complete the charge during the next charge cycle When the charger DC cord is unplugged the warning light will illuminate and remain illuminated for 10 sec onds if the charge is less than 9096 complete but the vehicle has enough power for 60 minutes of operation This will alert the fleet operator that the vehicle may be used but that it must be charged to completion as soon as possible The warning light will repeatedly illuminate for 10 seconds at 4 second intervals if the charger times out at 16 hours and the batteries are not sufficiently charged This indicates an abnormal charge cycle The charger and batteries should be checked by your Club Car distributor dealer The warning light will repeatedly illuminate for 10 seconds at 4 second intervals during a charge cycle DC plug is still connected if AC power to the charger is interrupted The warning light will go out when AC power is restored THE CHARGE CIRCUIT
165. tate of charge can be determined from the following table SPECIFIC GRAVITY AT 80 STATE OF CHARGE If the difference between the cells is 020 or more the low cell should be suspected It may require a catch up charge or it may be a weak cell When the variations between cells reach 050 or more the battery with the low cell should be replaced Page 13 10 1998 1999 PowerDrive Plus Maintenance and Service Supplement Battery Testing BATTERIES CORRECTED SPECIFIC GRAVITY BATTERY ELECTROLYTE CORRECTION REQUIRED NO TEMP FACTOR CELL 1 CELL 2 CELL ACTION 12 1 20 F 024 1 275 1 280 1 280 1 280 Good Battery 024 1 251 024 1 256 024 1 256 024 1 256 Fully Charged 35 6 90 F 004 1 155 004 1 1 1 165 004 1 1 1 160 004 1 1 1 165 004 1 1 Discharged Battery 59 69 64 69 Recharge 54 3 50 F 012 1 260 1 200 1 270 1 270 Bad No 2 Cell 012 1 248 012 1 188 012 1 258 012 1 258 69 5 80 F 000 1 250 0 1 250 1 255 0 1 255 1 230 0 1 230 1 250 0 1 250 Weak No 3 Cell Catch up Charge 38 2 100 F 008 1 200 008 1 2 1 180 008 1 1 1 170 008 1 1 1 180 008 1 1 Discharged Battery 08 88 78 88 Recharge and Recheck 22 4 80 F 000 1 240 0 1 240 1 245 0 1 245 Float Does 1 250 0 1 250 No 3 Cell Dead Not Rise Replace Battery If the previous tests have failed to identify the problem conduct a discharge test The discharge test comes closest to simulating actual vehicle
166. teering column in the center dash panel will illuminate intermittently If the battery warning light is illuminated after a charge cycle refer to the Troubleshooting Guide and Flow Charts on pages 14 8 through 14 12 If the specified test procedures do not identify any problems plug the DC cord into the vehicle and let it charge until the charger shuts off automatically If a problem is found correct it and then charge the vehicle Normal voltage toward the end of a charge cycle should be approximately 59 to 63 volts while the charger is still operating START CHARGE CYCLE 1 Disconnect the DC plug from the vehicle s charger receptacle 2 WAIT 20 SECONDS then reconnect the DC cord See following NOTE NOTE THE CHARGER WILL NOT OPERATE UNLESS A DELAY OF APPROXIMATELY 20 SECONDS IS OBSERVED 3 Monitor the ammeter for the charge rate If the vehicle has not been driven since the last charge cycle and the batteries are fully charged the onboard computer will not perform a self diagnostic test The charge cycle will begin and the ammeter will NOT drop to zero If the vehicle has been driven even if only a few feet the onboard computer will perform the self diagnostic test the ammeter will drop to zero for 2 to 3 seconds before the charge cycle begins A WARNING KNOWLEDGE OF BATTERY CHARGER WIRING AND COMPONENT TERMINOLOGY IS REQUIRED BEFORE ATTEMPTING ANY REPAIRS FIGURES 14 4 AND 14 5 PAGES 14 7 AND 14 8 DC
167. test which lasted 45 minutes battery No 1 is clearly shown to be the problem Battery No 4 should be watched a little more closely but appears to be okay Battery No 1 should be replaced with a battery that has about the same age and usage as the other batteries Example 2 Vehicle No 70 was also suspected of having a defective battery due to its performance The battery charger test showed 7 0 amps after a full charge After confirming there were no problems with the electrical system charger or brakes the on charge voltage was recorded as follows ON CHARGE VOLTAGE 10 48 10 53 10 57 10 55 10 33 Battery No 2 was immediately suspected as the problem After checking battery No 2 with a hydrometer it was discovered that the negative post cell was completely dead Battery No 2 should be replaced with a battery that has the same age and usage as the other batteries 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 13 13 BATTERIES Battery Storage BATTERY STORAGE Read DANGER and WARNING on page 13 1 When storing batteries during the off season or when maintaining a replacement stock follow these guidelines 1 Keep the batteries clean and free of corrosion as outlined in Battery Care page 13 5 2 Batteries that are in vehicles for winter storage should be left disconnected in the vehicles if the batteries are not going to be connected to a charger 3 Fully charge the batteries prior to storage 4 S
168. the warning light will illuminate for 10 seconds if the charge is less than 90 complete LED Light In addition to the warning light there is an infrared LED in the dash light assembly which transmits an infrared signal from the OBC This signal is received by the optional Communication Display Module which provides information on the condition of the vehicle and batteries See page 11 22 Solid State Speed Control Circuit The Control Circuit performs the following functions 1 Monitors vehicle ground speed through the motor speed sensor 2 Regulates vehicle ground speed by using the multi step potentiometer to determine accelerator pedal position 3 Activates the reverse buzzer when the Forward Reverse rocker switch is in REVERSE 4 Regulates direction of vehicle movement through the Forward Reverse switch 5 Activates the solenoids Tow Run Switch Circuit The Tow Run switch performs the following functions 1 Provides power to the key switch and the dash warning light when in the RUN position 2 Provides power to the No 18 white OBC wire when in the RUN position 3 Deactivates the vehicle s control circuit when in the TOW position THE POWER CIRCUIT The function of the power circuit is to supply voltage from the battery pack to the motor When regenerative motor braking is activated the power circuit will direct motor generated current to either the batteries or the energy dis placement module depending on the battery pa
169. tore in a cool area The colder the area in which the batteries are stored the less the batteries will self dis charge Batteries stored at 0 F will discharge very little over a four month period Batteries stored at 80 F will have to be recharged every few weeks 5 PowerDrive Plus vehicles and PowerDrive Chargers are designed to be left connected with AC power to the charger ON during off season storage The PowerDrive storage charge feature will automatically charge the batteries as needed throughout the storage period CHARGING BATTERY PACK WITH LOW VOLTAGE Read DANGER and WARNING on page 13 1 A WARNING ALWAYS UNPLUG THE ELECTRICAL CORDS BEFORE ATTEMPTING ANY REPAIRS TO THE CHARGER FIRST UNPLUG THE AC CORD FROM THE OUTLET AND THEN UNPLUG THE DC CORD FROM THE VEHICLE DC CORDSET HEAT SINK ASSEMBLY m S FUSE Ass y AMMETER AC CIRCUIT BREAKER SECONDARY COIL PRIMARY COIL TRANSFORMER AC CORDSET Figure 13 10 PowerDrive Charger Wiring Diagram 1 Turn the key switch OFF and place the Forward Reverse rocker switch in NEUTRAL Leave the batteries con nected and leave the 23 Pin connector plug connected to the controller 2 If battery pack voltage is below 34 volts the charger will not activate The charger relay will have to be by passed in order for the charger to activate 3 Disconnect the DC cord from the charger receptacle and unplug the AC cord from the elec
170. trical outlet Page 13 14 1998 1999 PowerDrive Plus Maintenance and Service Supplement BATTERIES Charging Battery Pack With Low Voltage 4 Remove the eight screws securing the charger cover and remove the cover from the charger 5 Inside the charger locate the black wire 3 that goes from the circuit breaker to the relay and disconnect it from the circuit breaker terminal Make sure this wire does not touch the charger housing or any other charger components Figure 13 10 Page 13 14 6 Disconnect the transformer wire 4 from the relay and then connect this wire to the open terminal on the cir cuit breaker Figure 13 10 Page 13 14 7 Plug the DC cord into the charger receptacle first and then plug the AC cord into an electrical outlet 8 The charger should activate and begin to charge the batteries Allow the charger to operate for one or two hours See following WARNING A WARNING DO NOT LEAVE THE VEHICLE UNATTENDED WHILE IT IS CHARGING THE CHARGER OPERATING WITH A BYPASSED RELAY COULD SHORT AND POSSIBLY CAUSE A FIRE 9 After one or two hours disconnect the charger AC cord from the electrical outlet first Then disconnect the DC cord from the charger receptacle in the vehicle 10 Disconnect the transformer wire from the circuit breaker and connect it to the relay Reconnect the short black wire from the relay to the circuit breaker 11 Install the charger cover and the eight retaining screws 12 Plug t
171. ts DC measure the voltage of the battery pack between the positive post of battery No 1 and the negative post of battery No 6 Figure 14 10 Page 14 13 Normal no load voltage will be 50 to 52 volts for fully charged batteries The voltage of the battery pack must be over 32 volts DC in order to allow the onboard computer to close the charger relay If battery pack voltage is too low to start charger see Section 13 Batteries Charging Battery Pack With Low Voltage Test Procedure 2 Onboard Computer 1 Check the circuit breaker on the front of the charger and reset if necessary 2 Select a second charger that is normally connected to another vehicle and is known to operate properly Leave the AC cord of the second charger connected to the AC outlet that it normally is connected to This will ensure AC power is present 3 Insert the DC cord from the second charger into the receptacle of vehicle that is not charging properly 4 Ifthe second charger fails the same manner as the first charger then the vehicle charging circuit is not func tioning properly See Troubleshooting Page 14 8 5 Connect the first charger into another vehicle that is known to be functioning properly If the charger per forms as it should then the charger is not in need of repair xX PLACE MULTIMETER RED LEAD HERE FRONT OF VEHICLE CHARGER RECEPTACLE PLACE MULTIMETER GRAY WIRE BLACK LEAD HERE FROM COMPUTER FUSE NO 6 BLACK Figu
172. ure Circuit Open 1 Place Tow Run switch in the TOW position and disconnect the batteries Figure 15 1 Page 15 2 2 Using two wrenches to prevent post from turning disconnect wires from the A1 and A2 terminals on the motor Using a multimeter set to 200 ohms 34 place the red probe on the A1 terminal and black probe on the A2 terminal Figure 15 1 Page 15 2 The multimeter should indicate continuity If the reading is incorrect a possible open or poor contact in a brush assembly and or open armature windings may be the cause The motor will need to be removed from the vehicle and repaired by a qualified technician See Motor Removal Test Procedure 3 Field Circuit Open 1 Place Tow Run switch in the TOW position and disconnect the batteries Figure 15 1 Page 15 2 2 Using two wrenches to prevent post from turning disconnect wires from the motor F1 and F2 terminals Using a multimeter set to 200 ohms place the red probe on the F1 terminal and the black probe on the F2 ter minal Figure 15 1 Page 15 2 The multimeter should indicate continuity If the reading is incorrect a possi ble open field coil or bad connections at the terminals may be the cause The motor will need to be removed from the vehicle and repaired by a qualified technician See Motor Removal Club Car
173. usting block to expand the fingers until they are wedged under the bottom edge of the guide ring Remove the guide ring by quickly and forcefully sliding the ram up the tool shaft and against the stop Figure 15 13 Page 15 11 The guide ring may also be removed using a small pry bar Guide Ring Installation 1 Coat the outside surface of the new guide ring with a thin film of guide ring adhesive Club Car Part No 101813201 then slide the guide ring onto the guide ring installation tool Figure 15 11 Page 15 9 next to the guide ring already in place Mating the splines of the input shaft with the splines in the armature shaft insert the input shaft into the armature shaft until the new guide ring is seated against the end of the arma ture splines Remove the guide ring installation tool from the armature Make sure the guide ring remains seated 2 After the guide ring is installed allow the glue to set for 24 hours before installing the snap ring 20 and installing the motor onto the transaxle Figure 15 8 Page 15 7 GUIDE RING GLUED TO INPUT SHAFT TO MAKE A GUIDE RING ALIGNMENT AND INSTALLATION TOOL GUIDE RING WITH ADHESIVE TO BE a ARMATURE Wes LR V D TRANSAXLE INPUT SHAFT CLUB CAR PART NO 1013764 GUIDE RING ALIGNMENT AND INSTALLATION TOOL AFTER A GUIDE RING IS GLUED TO THE SHAFT Figure 15 11 Guide Ring RECONDITIONING THE MOTOR Read DANGER and WARNING on page 15 1 Motor reconditioning must be perform
174. ut within 0 7V Battery reads below 9 8V or differs more romei Old batteries go to hydrometer test than 0 7V Replace battery Vehicle may not have been fully charged Send it back out to see if problem reoccurs Hydrometer Test If still having problems go to Page 13 8 hydrometer testing No apparent problems Very low reading or no reading at all Battery with variation of more than Discharge Test Battery has a dead cell Replace battery 050 between cells Replace battery Page 13 11 Within 0 3 volts of each other but Discharge time is low and battery If discharge time is 60 minutes or low discharge time End of battery set shows a variance greater than 0 4V at more problem is not with the batteries useful life Replace set end of discharge Replace battery Go to Section 14 PowerDrive Battery Charger Figure 13 7 Troubleshooting Chart 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement 13 9 BATTERIES Battery Testing 7 Repeat steps 2 through 6 on all cells VIEW AT EYE LEVEL Figure 13 8 Hydrometer Hydrometer Calibration Most hydrometers are calibrated to read correctly at 80 F The readings obtained as described above must be cor rected for temperature For each 10 F above 80 F add 004 to the reading For each 10 F below 80 F subtract 004 from the reading Interpreting the Results of the Hydrometer Test The approximate s
175. ve remaining wires and batteries See Figure 13 5 Page 13 4 for PowerDrive Plus Vehicle battery wiring 2 Visually inspect the new batteries for any damage that may have occurred in transit 3 If old battery cables are going to be reused inspect them for broken or frayed wires damaged terminals or worn insulation Remove any corrosion on the connectors One cup of bicarbonate of soda baking soda in gallon of water and a bristle brush do an excellent job of neutralizing and removing the corrosion Be careful not to allow this baking soda solution to enter the battery 4 PLACE TOW RUN SWITCH IN THE TOW POSITION BEFORE REMOVE NEGATIVE DISCONNECTING BATTERY CABLE FIRST CABLES Figure 13 5 PowerDrive Plus Battery Configuration 4 Check and clean the battery rack and hold downs The nuts and bolts on the hold downs may corrode It is therefore advised that they be cleaned periodically and replaced as necessary 5 Install batteries in the proper orientation Figure 13 5 Page 13 4 Install battery hold downs The hold downs should be tight enough so batteries do not move while vehicle is in motion but not so tight as to crack or buckle battery case Tighten to 40 in Ib 4 5 N m alternating between hold down bolts Page 13 4 1998 1999 PowerDrive Plus Maintenance and Service Supplement BATTERIES Battery Care 6 Install wires in proper sequence Figure 13 5 Page 13 4 Install black wire to negative post of battery No 6 last
176. werDrive Plus Vehicle Maintenance and Service Supplement Page 15 7 Testing and Inspecting Individual Components MOTOR COMPONENTS 1 Inspect the insulators 4 and 7 for cracks or other damage Figure 15 8 Page 15 7 2 Inspect the brushes 13 for damage or excessive wear Figure 15 8 Page 15 7 If brushes need to be replaced see NOTE in step 2 page 15 10 3 Inspect the brush springs 14 Replace springs that are discolored from heat light gold or blue tinted Replace springs which apply a force of less than 16 oz Figure 15 9 Page 15 8 A CAUTION WHEN CHECKING BRUSH SPRING TENSION DO NOT OVER EXTEND THE SPRING USING EXCESSIVE FORCE WILL DAMAGE THE SPRING BEARING INSPECTION 1 Using a clean cloth wipe the carbon dust off of the bearing Inspect the bearing by spinning it by hand and checking for both axial A and radial B play Figure 15 10 Page 15 8 2 Replace the bearing if itis noisy does not spin smoothly or has excessive play Check the bearing and replace if rusted worn cracked or if there is an abnormal color change in the metal of the bearing Do not remove the bearing unless it is to be replaced REPLACE SPRINGS WHICH APPLY A FORCE OF LESS THAN 16 OUNCES Figure 15 9 Check Brush Springs Figure 15 10 Inspect Bearing BEARING REMOVAL 1 Place the wedge attachment tool Club Car Part No 1012812 between the bearing 15 and the armature Figures 15
177. wire to heat sink to 18 in lb 2 0 N m See following NOTE NOTE e THE CHARGER RELAY BLADE CONNECTOR IS LOCATED OFF CENTER WITHIN THE RELAY HOUSING WHEN CONNECTING VOLTAGE SUPPRESSOR SLIP ON CONNECTOR TO RELAY BLADE CONNECTOR MAKE SURE SLIP ON CONNECTOR IS POSITIONED SO THAT FLAT SIDE OF CONNECTOR IS CLOSEST TO RELAY HOUSING SEE FIGURE 14 21 PAGE 14 24 CHARGER RELAY Charger Relay Removal 1 EN 00 1 Disconnect the AC and DC cords See WARNING on page 14 21 Remove the charger cover Disconnect the red blue black and primary coil wires from the relay Figure 14 21 Page 14 24 Remove the two nuts and lock washers attaching relay to charger base Figure 14 21 Page 14 24 Remove the relay TAN WIRE TO PRIMARY COIL WHITE WIRE FROM AC CORD GREEN GROUND WIRE BLACK WIRE TO STRAIN RELIEF POWER RELAY BLACK WIRE TO CIRCUIT BREAKER AC CORD BLUE WIRE TO DC CORD VOLTAGE SUPPRESSOR RED WIRE TO a AC CIRCUIT HEAT SINK SS BREAKER TAN WIRE TO PRIMARY COIL CHARGER RELAY Figure 14 21 Charger Relay Page 14 24 1998 1999 PowerDrive Plus Maintenance and Service Supplement POWERDRIVE BATTERY CHARGER Charger Repairs Charger Relay Installation 1 Install in reverse order of removal Connect wires as shown in Figure 14 21 Page 14 24 Tighten nut con necting relay to charger base to 18 in Ib 2 0 N m CHARGER AC CIRCUIT BREAKER AC Circuit Breaker Removal 1 Disconnect the
178. y 12 9 Ieceptacle F se Elnk ber gaat 12 10 Multi step Potentiometer 12 11 Multi step Potentiometer Arm Adjustment 12 13 Multi step Potentiometer Arm Brush Replacement 12 14 Multi step Potentiometer Adjustment 2 22 12 15 i e p m NC HR EE 12 15 Battery Warming Light sedere de tied ded the e ka dde dd he ded hd de nea d nds 12 16 Energy Displacement Module eee tenente dnte Lantern nnda 12 18 2 ht eet ect tee fetta r 12 19 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page iii SECTION 13 BATTERIES General Informator Common Misconceptions About Batteries Replacing Batteries t eet eget Battery Gare diee a eed Lite desee b ee edu ees Pr ventive Maintenance ene al een pep rte EE da e vede eect eee Self Discharge tee ees cadets de ted r duro itp a ird itu ced natuss ee baat seats Electrolyte evel E e RE e RR za he ROT NRI Pp seek Mineral Content
179. y discharge during long term storage Pin 6 provides voltage input WIRE to the OBC when the accelerator pedal is depressed to power up the system PIN 4 WHITE WIRE Controller varies vehicle ground speed depending on voltage input from the multi step PIN 7 potentiometer through the yellow black wire as the accelerator pedal is depressed 3 5 volts YEL BLK s i j WIRE with pedal up zero volts with pedal fully depressed Vehicle will not operate if voltage is below 3 0 volts when key switch is turned ON High Pedal Detect PIN 8 Pin 8 completes the negative voltage circuit for the multi step potentiometer through the pt WHT BLK i E WIRE white black wire ac olololololo red green wire 7 100 110 120 137 149159 PIN 15 Pin 15 supplies a constant 5 0 volts from the controller to the motor speed sensor through the PIN 14 Motor speed sensor acts as an electronic tachometer that pulses a voltage signal through the Ges GREEN light green wire at Pin 14 in the controller This signal tells the controller the vehicle s speed When the batteries can accept a regenerative charge the onboard computer provides a 13 volt PIN 13 GREEN WIRE input to the controller which causes the controller to switch from dynamic braking to regenerative braking Pin 12 completes the negative circuit for DB solenoid activating coil through the brown wire which closes solenoid contacts during normal operation Pin 12 shuts off voltage to DB sol

1998-1999 Maintenance and Service Manual Supplement

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