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Club Car 1995 Golf Car Maintenance Service Supplement

1995 ds electric golf car with powerdrive system 48
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1995 DS ELECTRIC
GOLF CAR WITH
POWERDRIVE SYSTEM 48
MAINTENANCE
S E R V I C E
SUPPLEMENT
USE WITH 1994
DS GASOLINE/ELECTRIC
MAINTENANCE AND
SERVICE MANUAL
PUBLICATION PART NO.1018293-05
PRINT CODE 0695B0895A

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Summary of Contents for Club Car 1995 Golf Car

  • Page 1 1995 DS ELECTRIC GOLF CAR WITH POWERDRIVE SYSTEM 48 MAINTENANCE S E R V I C E SUPPLEMENT USE WITH 1994 DS GASOLINE/ELECTRIC MAINTENANCE AND SERVICE MANUAL PUBLICATION PART NO.1018293-05 PRINT CODE 0695B0895A...

  • Page 3: General Information

    FLUSH WITH WATER FOR 15 MINUTES. CALL PHYSICIAN IMMEDIATELY. GENERAL INFORMATION Club Car has manufactured two versions of the PowerDrive System 48 vehicle. The earlier version used a multi-step (wiper switch) potentiometer in the speed control circuit, whereas the current version, beginning with week A9529, uses a continuously variable potentiometer.

  • Page 4: Powerdrive Vehicle Electrical Circuits

    Battery Trouble Light, see Section 19, Page 19-2). OBC data can also be useful in per- forming electrical system diagnostics. A digital readout of OBC data can be obtained using the Club Car Communication Display Module (CDM)(Club Car Part No. 1018318-01)(See page 17-22).
  • Page 5 # 18 RED / WHITE FIGURE 17-2 17-3...
  • Page 6 # 18 RED / WHITE FIGURE 17-3 17-4...

  • Page 7: The Power Circuit

    The on-board fuse link provides additional protection to the vehicle charging circuit. The fuse is rated for use only with a Club Car PowerDrive charger. If it is blown, the cause should be determined before it is replaced. A vehicle with a blown fuse will not charge (See Receptacle Fuse Link, Section 19).

  • Page 8: Troubleshooting Guide

    TROUBLESHOOTING GUIDE DIAGNOSTIC REFERENCE CHARTS Use these charts as a starting point for system troubleshooting. More detailed system testing instructions fol- low these charts. Battery / Charge Trouble Light In Dash Is Glowing DC plug DC plug is Wet sense Charge interrupt is connected disconnected...
  • Page 9 POWERDRIVE TROUBLE SHOOTING GUIDE SYMPTOM PROBLEM POSSIBLE CAUSES REFER TO Vehicle will not run - Batteries 1) battery connections Test Procedure 1 no solenoid "click" 2) batteries discharged Key Switch 1) loose wires Test Procedure 2 2) failed switch F&R Anti-arcing 1) loose wires Limit Switch 2) failed switch...
  • Page 10 POWERDRIVE TROUBLE SHOOTING GUIDE SYMPTOM PROBLEM POSSIBLE CAUSES REFER TO Vehicle runs slowly Wiring 1) improperly wired Figure 17-2 or 17-3 Batteries 1) loose terminals or corrosion Test Procedure 1 2) improper wiring & Battery, Section 18 3) failed batteries 4) discharged batteries Battery Charger, Section 19...

  • Page 11: Circuit Testing

    The numbers on the probe symbols indicate test procedure numbers. • A volt-ohm meter (VOM)(Club Car Part No. 1011480) or a continuity tester (Club Car Part No. 1011273) is needed in order to make these tests.
  • Page 12 # 18 RED / WHITE FIGURE 17-5 17-10...
  • Page 13 # 18 RED / WHITE FIGURE 17-6 17-11...

  • Page 14: Control Circuit

    CONTROL CIRCUIT WARNING • WHEN MAKING ELECTRICAL TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. - REMOVE KEY. - PUT F&R SWITCH IN NEUTRAL. - DISCONNECT BATTERIES AS SHOWN, FIGURE 17-1, PAGE 17-2. - FOLLOW ALL PROCEDURES EXACTLY AS STATED. •...
  • Page 15 Test Procedure 3 - Forward/Reverse Anti-Arcing Limit Switch: NOTE • OF THE THREE LIMIT SWITCHES ON THE FORWARD/REVERSE SWITCH, THE FORWARD/ REVERSE ANTI-ARCING LIMIT SWITCH IS THE ONE CLOSEST TO THE VEHICLE BODY. 1. Place the red (+) probe of the VOM or continuity tester on the small activating coil stud of the solenoid that has the white/black and red wires connected to it.
  • Page 16 # 18 RED / WHITE FIGURE 17-7 17-14...
  • Page 17 # 18 RED / WHITE FIGURE 17-8 17-15...

  • Page 18: Power Circuit

    Test Procedure 5 - Solenoid Activating Coil: 1. Remove Diode terminal end from the small post on solenoid (with 18 gauge yellow wire attached). 2. Make sure that the diode direction is correct (Figure 17-2, Page 17-3, or Figure 17-3, Page 17-4). The red terminal end of Diode attaches to small post on solenoid (with 18 gauge red wire and 18 gauge white/black striped wire attached).
  • Page 19 SPEED CONTROL CIRCUIT Test Procedure 8 - Multi-step Potentiometer: 1. Disconnect the black and white No. 18 wires that are attached to controller terminals “2” and “3” (termi- nals “B” and “C” on early model vehicles) (see wiring diagram Figure 17-2, Page 17-3 to identify ter- minals) and connect ohm meter to wires.
  • Page 20 Test Procedure 10 - Solid State Speed Controller: DANGER • TURN KEY SWITCH TO OFF, PUT THE F&R SWITCH IN NEUTRAL, AND DISCONNECT THE BATTERY CABLES AS SHOWN IN FIGURE 17-1, PAGE 17-2. FAILURE TO DO THIS MAY CAUSE THE VEHICLE TO RUN OVER YOU, RESULTING IN SEVERE INJURY OR DEATH! WARNING •...
  • Page 21 2.2. Reconnect batteries (Figure 17-1, Page 17- 2). 2.3. Place the Forward/Reverse Switch in either forward or reverse, turn the key on, and depress the accelerator pedal until limit switches turn on. This should cause the solenoid to operate with an audible click.
  • Page 22 Test Procedure 11 - On-board Computer Lockout Circuit: 1. Inspect the charger receptacle for water in the contacts. If water is found, proceed as follows: NOTE • IF THE BATTERY PACK IS WET, MAKE SURE THAT THE NO. 10 GREY WIRE FROM THE RECEP- TACLE IS NOT TOUCHING ANY OF THE BATTERIES.
  • Page 23 With the limit switch lever depressed, readings should be: COM to NC: Infinity (or continuity tester is not illuminated) FORWARD AND REVERSE SWITCH COM to NO: Zero (or continuity tester is illumi- nated) REVERSE HALF-SPEED LIMIT SWITCH 3. If meter readings are not correct, replace limit (F&R No.

  • Page 24: The Communication Display Module (Cdm)

    Func4 - 2 = DVDT, 4 = Normal, 8 = Max. timer). Trouble Light should be illuminated), the vehi- POWER Club Car cle’s batteries need to be recharged before PART #17075 being used again. This data can be used to make sure that all vehicles in a fleet receive equal usage on a short term basis.
  • Page 25 NOTE • THE VALUES OF ALL FOUR FUNCTIONS CAN BE RECALLED BY PRESSING AND RELEASING THE CDM BUTTON. 45° Club Car POSITION CDM SO THAT IT IS ALIGNED BODY OF CDM SHOULD BE POSITIONED DIRECTLY BEHIND THE ON-BOARD COMPUTER AT APPROXIMATELY 45° TO GRADE...

  • Page 26: Communication Display Module Troubleshooting Guide

    This condition may be corrected using a razor knife or a small cutting tool to remove any excess sealant material from the area around the projection lens. Use caution not to damage the lens when removing the sealant. See Club Car Service Bulletin No. 95-12 for complete information. 17-24...

  • Page 27: The Key Switch

    SECTION 17C - ELECTRICAL COMPONENTS WARNING • ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE SOME KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL REPAIR. FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL. •...
  • Page 28 Reconnect wires to key switch (See Figure 17-2, Page 17-3, or Figure 17-3, Page 17-4). Coat the terminals with Battery Protector Spray (CLUB CAR Part No. 1014305) to ward off corrosion. Reinstall in reverse order of removal. Be sure that key switch terminals can not touch the frame and that the panel is properly seated and snapped in place.
  • Page 29 DANGER • TURN KEY SWITCH TO OFF AND REMOVE KEY, PUT THE F&R SWITCH IN NEUTRAL, AND DISCONNECT THE BATTERY CABLES AS SHOWN IN FIGURE 17-1, PAGE 17-2. FAIL- URE TO DO THIS MAY CAUSE THE VEHICLE TO RUN OVER YOU, RESULTING IN SEVERE INJURY OR DEATH! Testing the Forward/Reverse Switch: 1.
  • Page 30 F&R ANTI-ARCING LIMIT SWITCH REVERSE BUZZER LIMIT SWITCH REVERSE HALF-SPEED LIMIT SWITCH SEAT SUPPORT FRONT PANEL FIGURE 17-14 F&R Lever Position Limit Switch Forward Reverse F&R Anti-arcing Depressed Depressed Half-speed Reverse Released Depressed Reverse Buzzer Released Depressed F&R Limit Switches Continued: Installing limit switches: Install in reverse order of disassembly.

  • Page 31: The Reverse Buzzer

    1. Using the wire stripper/crimper, strip the wire from the harness back 5.6 mm (1/4 inch). 2. Insert wire end into butt connector on new resistor wire assembly (CLUB CAR Part No. 1018830-01). 3. Using the wire crimper, crimp the butt connector to permanently attach it to the wire from the harness.
  • Page 32 Testing the Reverse Buzzer, Continued: 4. Remove center dash. 4.1. Remove the plastic cap covering the screw on each side of the center dash. 4.2. Loosen (but do not remove) the screw on each side of the center dash panel. 4.3.

  • Page 33: Testing The Solenoid

    THE SOLENOID The solenoid is located on the passenger’s side fender well behind the battery compartment. The solenoid has two sets of posts; two 5/16 inch posts (power contact posts) and two small No. 10 posts (activating coil posts). WARNING •...
  • Page 34 DANGER • TURN KEY SWITCH TO OFF AND REMOVE KEY, PUT THE F&R SWITCH IN NEUTRAL, AND DISCONNECT THE BATTERY CABLES AS SHOWN IN FIGURE 17-1, PAGE 17-2. FAIL- URE TO DO THIS MAY CAUSE THE VEHICLE TO RUN OVER YOU, RESULTING IN SEVERE INJURY OR DEATH! WARNING •...

  • Page 35: On Board Computer (Obc)

    Removing the resistor: 1. Disconnect batteries (Figure 17-1, Page 17-2). 2. Discharge the controller (See instructions in Warning Box on Page 17-25). WARNING • FAILURE TO DISCHARGE THE CONTROLLER COULD RESULT IN A SHORT SHOULD THE WRENCH OR RATCHET TOUCH THE LARGE POST DURING REMOVAL OR INSTALLATION OF THE RESISTOR OR DIODE ASSEMBLY.

  • Page 36: Solid State Speed Controller

    Removing The On-board Computer, Continued: CHARGER RECEPTACLE NO. 10 BLACK WIRE TO OBC GREY WIRE FROM OBC TERMINAL LOCK NUTS FUSE ASSEMBLY GREY LEAD WITH NO. 10 BLACK MALE CONNECTOR NO. 6 BLACK FIGURE 17-15 FIGURE 17-16 3. Disconnect the No. 10 black wire (to the OBC) from the back of the charger receptacle (Figure 17-15). 4.

  • Page 37: Charger Receptacle

    4. Unplug the three No. 18 wires plugged into the controller (Figure 17-16). 5. Remove the four 7/16 lock nuts holding the controller (Figure 17-16). 6. Remove the controller from the vehicle. Installing the Solid State Speed Controller: Install in reverse order of disassembly. CHARGER RECEPTACLE Testing the Charger Receptacle: See Section 19, See Test Procedure 1, Page 19-13...

  • Page 38: Receptacle Fuse Link

    Installing a New Receptacle (Figure 17-17, Page 17-35): 1. Install the bezel (7) with four screws (9) through the bezel and body and into the receptacle backing plate (8). Torque screws to 9-13 in.lbs. (1.0/1.5 N-m). 2. Thread the No. 10 red wire (4) through the tie wraps on the front body support and attach the connec- tor to the positive post of battery No.

  • Page 39: Continuously Variable Potentiometer

    WARNING • WHEN MAKING ELECTRICAL TESTS OR REPAIRS, ALWAYS: • WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. • REMOVE KEY. • DO NOT WEAR LOOSE CLOTHING. REMOVE JEWELRY SUCH AS RINGS, WATCHES, CHAINS, ETC. BEFORE SERVICING VEHICLE. • PUT F&R SWITCH IN NEUTRAL. •...
  • Page 40 Removing the Continuously Variable Potentiometer, Continued: TO WIRE HARNESS FIGURE 17-18 4. Slide the center dash panel up the steering column by snapping out the top and then rotating the panel out and up. There is sufficient slack in the wiring to allow for this. 5.
  • Page 41 13. Remove the 1/4 bolt (15), washer, and nut attaching the actuator lever (6) to the accelerator pivot rod (Figure 17-18). 14. Remove the pivot rod. NOTE • THERE IS A NYLON WASHER (16) BETWEEN THE ACTUATOR LEVER AND THE POTEN- TIOMETER HOUSING.

  • Page 42: Multi-Step Potentiometer

    MULTI-STEP POTENTIOMETER WARNING • WHEN MAKING ELECTRICAL TESTS OR REPAIRS, ALWAYS: • WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. • REMOVE KEY. • DO NOT WEAR LOOSE CLOTHING. REMOVE JEWELRY SUCH AS RINGS, WATCHES, CHAINS, ETC. BEFORE SERVICING VEHICLE. • PUT F&R SWITCH IN NEUTRAL. •...
  • Page 43 POTENTIOMETER TYPICAL 2 PLACES POTENTIOMETER MOUNTING FIGURE 17-19 5. Connect the No. 18 green/white wire to F&R limit switch No. 1. Connect the No. 18 black (2), white (3), and blue (4) wires to the multi-step potentiometer. 6. Connect the accelerator rod (1) to the potentiometer. 7.

  • Page 45: Section 18 - Batteries

    SECTION 18 - BATTERIES WARNING • ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE SOME KNOWLEDGE AND EXPE- RIENCE IN GENERAL ELECTRICAL REPAIR. FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL. •...
  • Page 46 General Information Continued: The batteries supplied with an electric vehicle must supply 100% of the energy required to move the vehicle. These batteries therefore receive deep discharge down to 30% to 40% of their full charge capacity. Then they must be recharged, hence their name “deep cycle.” The average amperage draw is considered to be 75 amps on a 36 volt car, and 56 amps on a 48 volt car, although it varies greatly depending on the vehicle and how it is operated.

  • Page 47: Common Misconceptions About Batteries

    CHARGER PbSO 4 PbSO DISCHARGED BATTERY BATTERY CHARGING FIGURE 18-3 FIGURE 18-4 COMMON MISCONCEPTIONS ABOUT BATTERIES This chart cannot and does not describe all problems which may be encountered with batteries, but it does identify some of the common misconceptions and problems. PROBLEM MISCONCEPTION AND REALITY Deep Discharge...

  • Page 48: Replacing Batteries

    REPLACING BATTERIES DANGER • WEAR A FULL FACE SHIELD WHEN WORKING AROUND BATTERIES BECAUSE OF THE DAN- GER OF AN EXPLODING BATTERY. • BATTERY - EXPLOSIVE GASES - DO NOT SMOKE! KEEP SPARKS, FLAMES, CIGARETTES AWAY. TOOLS, WIRES AND METAL OBJECTS CAN CAUSE SPARKS WHEN “SHORTED” ACROSS A BATTERY.

  • Page 49: Battery Care

    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 con- nected, coat all terminals with Battery Protector Spray (CLUB CAR Part No.1014305) to ward off future corrosion.

  • Page 50: Mineral Content

    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.

  • Page 51: Battery Charging

    BATTERY CHARGING General Information The charger supplied with the CLUB CAR DS Electric Vehicle solves the most common problems in charg- ing. Undercharging and overcharging are prevented provided the charger is allowed to shut off by itself. Also, all cells are automatically given an equalization charge at low current, which prolongs battery life. Batteries should never be left in a discharged state, as this too affects the internal components and can reduce the capacity of the battery.

  • Page 52: Battery Testing

    NOTE • WHEN A FLEET OF POWERDRIVE SYSTEM 48 VEHICLES IS BEING ROTATED, THE CLUB CAR CDM (COMMUNICATION DISPLAY MODULE) CAN BE A TREMENDOUSLY HELPFUL SERVICE TOOL. BY MONITORING THE VALUE OF FUNCTION 3 WITH THE CDM, IT CAN BE DETER- MINED WHICH CARS SHOULD TO BE USED (SEE PAGE 17-21).

  • Page 53: Battery Troubleshooting Chart

    BATTERY TROUBLESHOOTING CHART Car not running to expectation Fully Charge Batteries Battery Charger Test Page 18-9 Reading of 8 Amps or more Reading below 8 Amps Check electrical system and charger On-Charge Voltage Test for problems. See Trouble- Shooting Guide, Page 19-11. Page 18-10 If problem is not found, go to on-charge voltage test.
  • Page 54 After 20 minutes, record the voltage of the battery set as well as the individual batteries, using the VOM, (CLUB CAR part No.1011480). Set the meter on 50 VDC. Place the red (+) probe at the positive terminal and the black (-) probe at the negative terminal of each battery. Record reading. The on-charge voltage for the set should read between 42.0 volts and 47.4 volts depending on the make, size and age of the battery being test-...

  • Page 55: Hydrometer Test

    VOM (CLUB CAR Part No.1011480). Set the meter on 100 VDC. Place the red (+) probe at the positive post of the battery No. 1 and the the black (-) probe at the negative post of battery No.

  • Page 56: State Of Charge

    Interpreting the Results of the Hydrometer Test The approximate state of charge can be determined from the following table: SPECIFIC GRAVITY AT 80° STATE OF CHARGE 1.250 - 1.280 100% 1.220 - 1.240 1.190 - 1.210 1.160 - 1.180 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.

  • Page 57: Discharge Test

    The discharge test is the hardest test on the batteries and the most time-consuming to perform. Use the bat- tery discharge tester (CLUB CAR Part No.1018319-01). This discharge tester can be used on both 36 volt V- Glide and 48 volt Powerdrive vehicles.
  • Page 58 DANGER • WEAR A FULL FACE SHIELD WHEN WORKING AROUND BATTERIES BECAUSE OF THE DAN- GER OF AN EXPLODING BATTERY. • BATTERY - EXPLOSIVE GASES - DO NOT SMOKE! KEEP SPARKS, FLAMES, CIGARETTES AWAY. TOOLS, WIRES AND METAL OBJECTS CAN CAUSE SPARKS WHEN “SHORTED” ACROSS A BATTERY.
  • Page 59 Interpreting 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 No. 6 above. If any bat- tery shows a 0.4 volt or greater variance, the battery is bad or nearing the end of its useful life and should be discarded or grouped with other batteries at or around same voltage.

  • Page 60: Battery Troubleshooting Examples

    Battery Troubleshooting Examples A few examples of troubleshooting battery problems should clarify the procedure. Example 1 Car No. 68 was suspected of having a bad 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 volt- age test was performed and the following results were recorded: V-Glide 36 volt Vehicle BATTERY NO.

  • Page 61: Battery Storage

    V-Glide 36 volt Vehicle BATTERY NO. DISCHARGE VOLTAGE 4.08* 5.50 5.80 5.36 5.57 5.56 PowerDrive System 48 Vehicle BATTERY NO. DISCHARGE VOLTAGE 5.44* 7.33 7.73 7.15 7.43 7.41 *After a discharge test which lasted 65 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.

  • Page 62: Specific Gravity

    V-Glide Storage Continued: 5. Check the state of charge periodically. Batteries that are discharged and left in a cold SPECIFIC GRAVITY FREEZING POINT environment can freeze and crack. If the spe- 1.260 -70°F cific gravity drops below 1.220, the batteries should be recharged.

  • Page 63: Section 19 - Powerdrive Battery Charger

    SECTION 19 - POWERDRIVE BATTERY CHARGER GENERAL INFORMATION The PowerDrive Battery Charger is an integral part of Club Car’s PowerDrive™ System 48, and one is includ- ed with every PowerDrive vehicle. Because it is controlled by the PowerDrive System 48 vehicle’s on-board computer, it will work with only PowerDrive System 48 vehicles.

  • Page 64: The Charge Circuit

    This indicates an abnormal charge cycle. The charger and batteries should be checked by your Club Car distributor/dealer. • The trouble light will come on during a charge cycle (DC plug is still connected) if AC power to the charg- er is interrupted.
  • Page 65 WARNING • DO NOT BY-PASS THE SENSE LEAD FUSE! • UNPLUG BOTH THE AC AND DC PLUGS BEFORE WORKING ON THE CHARGER OR CHANG- ING CHARGER CORD. • TO CONNECT THE CHARGER PLUG TO THE VEHICLE RECEPTACLE, GRASP THE PLUG AND PUSH IT STRAIGHT INTO THE RECEPTACLE.

  • Page 66: Charger Installation And Use

    CHARGER INSTALLATION AND USE The AC line to which the charger is to be connected must be capable of supplying at least 15 amperes to each charger. WARNING • EACH CHARGER SHOULD HAVE ITS OWN 15 OR 20 AMPERE BRANCH CIRCUIT PRO- TECTION (CIRCUIT BREAKER OR FUSE), IN ACCORDANCE WITH THE NATIONAL ELEC- TRICAL CODE ANSI/NFPA 70, AND LOCAL CODES AND ORDINANCES.
  • Page 67 NORMAL CHARGER OPERATION WARNING • CONNECT CHARGER ONLY TO A PROPERLY GROUNDED SINGLE PHASE (3 WIRE) OUTLET. • CHARGE BATTERIES ONLY IN A WELL VENTILATED AREA. • TO CONNECT THE CHARGER PLUG TO THE VEHICLE RECEPTACLE, GRASP THE PLUG AND PUSH IT STRAIGHT INTO THE RECEPTACLE.

  • Page 68: Checking Battery Condition After A Charge Cycle

    Normal Charger Operation Continued: 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.
  • Page 69 WARNING • STUDY AND BECOME FAMILIAR WITH THE WIRING AND TERMINOLOGY OF THE CHARGER BEFORE ATTEMPTING ANY REPAIRS (FIGURES 19-4 AND 19-5). D.C. CORDSET RECTIFIER ASSEMBLY BLUE BLACK BLACK 15 AMP A.C. CIRCUIT BREAKER SECONDARY RELAY COIL BLACK BLACK FUSE ASS'Y AMMETER PRIMARY COIL...

  • Page 70: Troubleshooting

    TROUBLESHOOTING Use the following charts (Pages 19-8 through 19-12) as guides for troubleshooting electric vehicles with PowerDrive System 48. The chart (below) on pages 19-8 and 19-9 refer specifically to the on-board computer and battery charger. The charts on pages 19-10 through 19-12 encompass the entire vehicle electrical sys- tem.
  • Page 71 TROUBLESHOOTING TROUBLESHOOTING CHART CONTINUED: COLUMN ONE COLUMN TWO CONTINUED FROM CONTINUED FROM PREVIOUS PAGE PREVIOUS PAGE WIRING CORRECT OR CORRECT AND DETERMINE CAUSE TIGHTEN WIRING FUSE BLOWN TIGHT AND REPLACE FUSE BY-PASS CHARGER CHARGE BATTERIES CHECK RED LINE CHARGE BATTERIES RELAY AS OBC FUSE DESCRIBED IN...
  • Page 72 TROUBLESHOOTING CONTINUED: WARNING • ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THE CHARGER. CONSULT YOUR CLUB CAR DISTRIBUTOR/DEALER. • ALWAYS WEAR SAFETY GLASSES OR EYE PROTECTION WHILE SERVICING VEHICLE OR CHARGER. • TURN KEY SWITCH OFF AND PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSITION PRIOR TO SERVICING THE CAR.
  • Page 73 POWERDRIVE BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Relay closes with an audible click Check AC outlet for proper voltage Test Procedure 3 but no transformer hum and ammeter does not move Failed AC plug and cord Test Procedure 3 Internal AC breaker Test Procedure 3 Transformer primary coil...
  • Page 74 POWERDRIVE BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Charger turns off too soon, Batteries may be fully charged Test Procedure 7 continued... Charger goes to 16 hour time out On-board computer malfunction Test Procedure 2 Extremely discharged batteries Recharge batteries or cold temperature Bad battery...

  • Page 75: Test Procedures

    TEST PROCEDURES GENERAL The charger uses DC battery voltage through the on-board computer to close the charger relay that 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.

  • Page 76: Test Procedure

    PLACE VOM LEADS HERE CHARGER FRONT OF RECEPTACLE VEHICLE GREY WIRE PLACE VOM FROM COMPUTER LEADS HERE FUSE ASSEMBLY GREY WIRE WITH MALE CONNECTOR #6 BLACK FIGURE 19-6 FIGURE 19-7 TEST PROCEDURE 2 - ON-BOARD COMPUTER: 1. Check the circuit breaker on the front of the charger and reset if necessary. 2.
  • Page 77 3. Check the AC line fuse or circuit breaker in the storage facility. 4. With VOM (Club Car Part No. 1011480) set at 500 VAC, check incoming AC voltage. Insert prongs into outlet; voltage should be 105 to 128 volts.
  • Page 78 Test Procedure 4, Continued: 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 rectifier assembly must be replaced. To check diodes: 1.
  • Page 79 CHARGER. FIRST UNPLUG THE AC CORD FROM THE OUTLET AND THEN UNPLUG THE DC CORD FROM THE VEHICLE. 1. Using the continuity tester (Club Car Part No. 1011273), connect the test leads to the pins marked (+) and (-) on the DC plug (Figure 19-11), and note the readings.
  • Page 80 5. If the AC line fuse or circuit breaker does blow, check the transformer secondary voltage across leads No.1 and No. 5 using a VOM (Club Car Part No. 1011480) . If measured voltages are approximately 85 volts or lower for the secondary coil, the transformer is shorted internally and must be replaced (Figure 19-13, Page 19-19).
  • Page 81 D.C. CORDSET RECTIFIER ASSEMBLY BLUE BLACK BLACK 15 AMP A.C. CIRCUIT SECONDARY BREAKER RELAY COIL BLACK BLACK FUSE AMMETER ASS'Y PRIMARY COIL A.C. INPUT PLUG GREEN CASE A.C. CORDSET GROUND WHITE FIGURE 19-13 CAUTION • ONLY TRAINED TECHNICIANS SHOULD ATTEMPT TO REPAIR OR SERVICE THIS CHARGER. ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD FOLLOW THE CORRECT PROCEDURES AND HEED THE WARNINGS STATED IN THIS MANUAL.
  • Page 82 3. Using a continuity tester (Club Car Part No. 1011273), put alligator clip on the end of the black wire and check for continuity on both flat prongs and on the ground prong of the AC plug (Figure 19-14).
  • Page 83 8. Move the continuity tester alligator clip to the black wire of the DC cord. 9. Place the continuity tester probe on the negative (-) prong of the DC plug. You should register continu- ity (bulb should light). If you do not register continuity, cord and plug must be replaced. 10.

  • Page 84: Plug And Receptacle Replacement

    PLUG AND RECEPTACLE REPLACEMENT 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 are becoming difficult to insert and remove, the receptacle contacts and plug pins can be cleaned with a good electrical contact cleaner or lightly sprayed with WD-40 ®...

  • Page 85: Charger Repairs

    NOTE • CHECK POSITION OF TERMINALS TO BE SURE THAT THEY ARE NOT TOUCHING THE AMMETER BUSS BAR (3) OR THE OTHER AMMETER POST (FIGURE 19-16). 5. Put the strain relief bushing on the cord and insert it into the charger base using pliers. 6.
  • Page 86 Removal of the Transformer (Figures 19-4 and 19-5, Page 19-7): 1. Remove the charger cover. 2. Disconnect the tan primary coil lead from the charger relay, then disconnect the white wire from the AC cord. 3. Disconnect the secondary transformer leads from the rectifier assembly. 4.
  • Page 87 FUSE LINK Removal of Fuse Link: 1. Remove the charger cover. 2. Remove both secondary transformer leads and the buss bar from the back of the fuse link assembly. 3. Remove screws from the front of the charger and remove the fuse link assem- bly.
  • Page 88 CHARGER AC CORD (FIGURE 19-18) Removal of the AC Cord: 1. Unplug the AC and DC cords. 2. Remove the charger cover. 3. Disconnect the AC cord black wire at the circuit breaker. 4. Disconnect the AC cord white wire at the primary coil. 5.
  • Page 89 Club Car PEDAL GROUP ADJUSTMENT INSTRUCTIONS ALL CLUB CAR VEHICLES New Pedal Group Incorporation Effective 2-6-95 Bulletin No. 95-5 (Revised)

  • Page 90: General Precautions

    ONLY TRAINED PEOPLE SHOULD SERVICE OR REPAIR THE VEHI- CLE. ANYONE SERVICING, REPAIRING, OR INSTALLING OPTIONAL EQUIPMENT ON A CLUB CAR VEHICLE, NO MATTER HOW SIMPLE THE OPERATION, SHOULD FOLLOW PROPER PROCEDURES AND HEED WARNINGS IN THIS AND ALL OTHER APPLICABLE PUBLI- CATIONS.
  • Page 91 IDENTIFYING THE NEW PEDAL GROUP (FIGURE 1). The new pedal group was incorporated 02/06/95 (Serial No. 445799 and greater) on electric vehicles, and on 02/07/95 (Serial No. 445519 and greater) on gasoline powered vehicles.The new pedal group differs from the old style in the following ways: 1.
  • Page 92 RAISE THE VEHICLE AND SECURE IT ON JACK STANDS. WARNING • LIFT ONLY ONE END OF THE VEHICLE AT A TIME. CHOCK THE WHEELS AND LOCK HILL BRAKE BEFORE LIFTING. USE A SUITABLE LIFTING DEVICE (CHAIN HOIST OR HYDRAULIC FLOOR JACK) WITH 1000 LBS. (454 KILOGRAMS) MINIMUM LIFTING CAPACITY. DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN ELEVATED POSITION.
  • Page 93 7.1. Using a 1/2” socket and 1/2” wrench, loosen nut and bolt (Items 1and 2, Fig- ure 3) securing accelerator pedal to pivot plate.Using the accelerator pedal adjustment tool (Club Car Part no. 1018710) clamped to the accelerator pedal, with “accelerator pedal height” toward floorboard, position pedal at 5- 5/8”...
  • Page 94 ADJUST ACTUATOR LEVER - ELECTRONIC CONTROLLER VEHICLES ONLY. (FIGURE 4) 8.1. Reposition and clamp the Accelerator Pedal Adjustment tool on the accel- erator pedal with the side marked “micro break point” towards the floor- board, then depress the accelerator until a pedal height of 4-5/8” plus or minus 3/32”...
  • Page 95 POTENTIOMETER HOUSING ASSEMBLY SIDE VIEW OF POTENTIOMETER HOUSING ASSEMBLY WITH COVER CUT AWAY POTENTIOMETER HOUSING ASSEMBLY FIGURE 4 Page 7...
  • Page 97 Club Car NOTES...
  • Page 98 Club Car NOTES...

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