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Club Car Gasoline Service Manual

1995-1996 ds golf cars
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1995-1996
MAINTENANCE
S E R V I C E
DS GOLF CARS
GASOLINE/ELECTRIC
MANUAL NUMBER 101905101
EDITION CODE 1196H0799C

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  Summary of Contents for Club Car Gasoline

  • Page 1 1995-1996 MAINTENANCE S E R V I C E DS GOLF CARS GASOLINE/ELECTRIC MANUAL NUMBER 101905101 EDITION CODE 1196H0799C...
  • Page 3 Club Car distributor’s/dealer’s representative or by a Club Car factory trained mechanic. It is the policy of Club Car, Incorporated to assist its distributors and dealers in continually updating their ser- vice knowledge and facilities so that they can provide prompt and efficient service for the vehicle owner.
  • Page 4: Table Of Contents

    PERIODIC MAINTENANCE SECTION Lubrication - Gasoline Vehicles ......................Lubrication - Electric Vehicles ......................Vehicle Capacities ..........................Periodic Service - Gasoline Vehicles ....................Periodic Service - Electric Vehicles ....................BODY AND TRIM SECTION General Information .......................... Front and Rear Body Repair ......................
  • Page 5 Floormat ............................ACCELERATOR AND BRAKE PEDAL GROUP SECTION General Information .......................... Pedal Group Adjustment - Early 1995 Vehicles ................Pedal Group Disassembly and Assembly - Early 1995 Vehicles ............Pedal Group Adjustment - Late 1995 and 1996 Vehicles ..............6-13 Pedal Group Disassembly and Assembly - Late 1995 and 1996 Vehicles ........
  • Page 6 TROUBLESHOOTING THE GASOLINE VEHICLE SECTION Troubleshooting Guide ........................11-1 ELECTRICAL SYSTEM - GASOLINE VEHICLE SECTION General Information .......................... 12-2 FE 290 Gasoline Vehicle Electrical Circuit ..................12-2 Circuit Testing ............................ 12-7 Test Procedures ..........................12-14 Electrical System Components ......................12-27...
  • Page 7 Starter/Generator .......................... 12-27 Voltage Regulator ......................... 12-38 Key Switch ............................ 12-39 Solenoid ............................12-40 Fuse .............................. 12-41 Limit Switches ..........................12-41 Neutral Lock-out Cam ........................12-44 Reverse Warning Buzzer ......................12-44 Oil Warning Light .......................... 12-46 Battery ............................12-46 FE 290 ENGINE SECTION General Information ..........................
  • Page 8 TRANSMISSION AND GOVERNOR SECTION General Information .......................... 17-2 Lubrication ............................17-2 Transmission ............................. 17-3 Forward and Reverse Shifter Cable ....................17-22 REAR SUSPENSION - GASOLINE VEHICLE SECTION General Information .......................... 18-1 Shock Absorbers ..........................18-1 Mono-Leaf Springs ........................... 18-3 The Snubber .............................
  • Page 9 Forward and Reverse Switch ......................20-27 Forward and Reverse Limit Switches .................... 20-28 The Reverse Buzzer ......................... 20-29 The Solenoid ............................ 20-31 On-Board Computer ......................... 20-33 Solid State Speed Controller ......................20-34 Charger Receptacle .......................... 20-34 Receptacle Fuse Link ........................20-36 Continuously Variable Potentiometer ....................
  • Page 10 ACCU-POWER BATTERY CHARGER SECTION General Information .......................... 23-1 The Charge Circuit ..........................23-3 Charger Installation and Use ......................23-3 Troubleshooting ..........................23-6 Test Procedures ..........................23-7 Plug and Receptacle Replacement ....................23-18 On-Board Receptacle Fuse Link ....................23-21 Charger Repairs ..........................23-22 Capacitor ............................
  • Page 11: Safety

    SECTION 1 - SAFETY To insure the safety of those servicing Club Car DS Golf Cars, and to protect the vehicles from possible dam- age resulting from improper service or maintenance, the procedures in this manual must be followed. It is important to note that throughout this manual there are statements which are contained within boxes labeled DANGER , WARNING , or CAUTION .
  • Page 12 USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE. • ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON- NECTIONS. GASOLINE VEHICLES ONLY: • TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE; ALWAYS, BEFORE SERVICING: - DISCONNECT BATTERY CABLES, NEGATIVE (-) FIRST.
  • Page 13: Vehicle Specifications

    SECTION 2 - VEHICLE SPECIFICATIONS Club Car, Inc. reserves the right to change specifications and design of either gasoline or electric vehicles at any time without notice and without obligation to make these changes on units previously sold. POWERDRIVE POWERDRIVE...
  • Page 14 Weight: Fairway Villager electric vehicle (without batteries) (225 kg) 593 lbs. Weight: Standard gasoline powered vehicle (dry) (269 kg.) 633 lbs. Weight: Fairway Villager gasoline powered vehicle (dry) (287 kg.) 12 - 15 mph 12 - 15 mph 12 - 15 mph 12 - 15 mph...
  • Page 15: General Information Section

    MODEL IDENTIFICATION The serial number of your CLUB CAR is on a stamped data plate (1995 and early 1996) or bar coded decal (most of 1996) mounted on the frame directly above the accelerator pedal (Example: A9601-123456 for Elec- tric or AG9601-123456 for Gasoline) (See Figure 3-1).
  • Page 16: Pre-Operation Checklist

    • General: All the parts should be in place and properly installed. Be sure that all nuts, bolts, and screws are tight. On the DS Gasoline vehicle, check all hose clamps for tight fit as well as the starter belt for tightness.
  • Page 17: Controls

    • DS Gasoline Governor: Check the speed of the vehicle. The vehicle should run at 12-15 MPH (19-24 KPH) on a level surface. • General: Listen for any unusual noises such as squeaks or rattles. Check the vehicle’s ride and perfor- mance.
  • Page 18 R (reverse), to run the vehicle in reverse. When the lever is in the straight up, or N (neutral) position, the vehicle will not run. The engine on the DS Gasoline will stop if it is shifted to neutral while it is running.
  • Page 19 Figure 3-8). FIGURE 3-7 FIGURE 3-8 GASOLINE VEHICLES ONLY: NEUTRAL LOCK-OUT - The vehicle has a neutral lock-out circuit that prevents the driver from starting the vehicle in NEUTRAL. If the vehicle is started in forward or reverse and then shifted to neutral, the engine will stop running. However, for the convenience of the trained mechanic, there is a neutral lock-out cam located on the back of the forward and reverse lever.
  • Page 20 OIL LIGHT - The DS Gasoline golf car is equipped with a low oil warning light, located on the dash panel just above the steering column (See Figure 3-12). If the oil warning light comes on, oil should be checked and added to the engine as necessary before continuing to use the vehicle.
  • Page 21 If the warning light comes on and the vehicle is unable to finish the round, have your Club Car distributor/dealer check the vehicle for a possible battery or electrical system problem.
  • Page 22: Driving Instructions

    DRIVING INSTRUCTIONS WARNING • IF RENTING OR LOANING THE VEHICLE, MAKE SURE THE DRIVER IS FAMILIAR WITH ALL CONTROLS AND OPERATING PROCEDURES BEFORE ALLOWING THE VEHICLE TO BE DRIVEN. • NO MORE THAN TWO PEOPLE SHOULD BE ON THE VEHICLE AT ONE TIME. •...
  • Page 23: Towing

    NOTE • THE VEHICLE OPERATOR MUST CONTROL SPEED WHEN GOING DOWNHILL. • GASOLINE VEHICLE ONLY: DEPRESS THE BRAKE PEDAL AS NECESSARY AND PARTIALLY DEPRESS THE ACCELERATOR WHEN DESCENDING A HILL. WITH THE ACCELERATOR PEDAL PARTIALLY DEPRESSED, THE ENGINE GOVERNOR WILL CAUSE THE ENGINE TO CONTROL DOWNHILL SPEED.
  • Page 24: Transporting On A Trailer

    • AVOID SUDDEN STARTS, SUDDEN STOPS, AND TIGHT TURNS WHEN TOWING. • DO NOT TOW MORE THAN ONE (1) VEHICLE WITH ANOTHER CLUB CAR. IF MORE THAN ONE VEHICLE MUST BE TOWED, A PROPERLY FITTED VEHICLE WITH A TOW HITCH HEIGHT OF 11 INCHES (28 CM) SHOULD BE USED.
  • Page 25 • GASOLINE - FLAMMABLE! EXPLOSIVE! DO NOT SMOKE. KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE. • NEVER ATTEMPT TO DRAIN GASOLINE WHEN THE ENGINE IS HOT OR WHILE IT IS RUN- NING. BE SURE TO CLEAN UP ANY SPILLED GASOLINE BEFORE OPERATING THE VEHICLE.
  • Page 26: Storage - Electric Vehicle

    (NOTE: Do not allow this solution to enter the batteries). Let the terminals dry and coat them with CLUB CAR battery terminal spray, Part No. 1014305. 3. Store in a cool, dry place. This will prevent self-discharge of the batteries.
  • Page 27 NOTE • A POWERDRIVE SYSTEM 48 VEHICLE WILL NOT OPERATE WHILE PLUGGED TO A CHARGER. 9. If PowerDrive System 48 and PowerDrive Plus vehicles cannot be connected to a charger during stor- age, disconnect the batteries as shown (Figure 3-13). TO RETURN THE STORED VEHICLE TO SERVICE: 1.
  • Page 28 Page 3-14...
  • Page 29: Periodic Maintenance

    SYSTEM. FAILURE TO HEED THIS WARNING COULD RESULT IN SEVERE BURNS. • ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON- NECTIONS. GASOLINE VEHICLES ONLY: • TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE; ALWAYS, BEFORE SERVICING: - DISCONNECT BATTERY CABLES, NEGATIVE (-) FIRST.
  • Page 30: Lubrication - Gasoline Vehicles

    REGULAR INTERVAL SERVICE PLACE* RECOMMENDED LUBRICANT Brake shaft bearings Dry Moly Lube - Club Car Part No. 1012151 Quarterly by Owner or Trained Technician Brake Linkage and Pivots Dry Moly Lube - Club Car Part No. 1012151 Accelerator push rod pivots and Dry Moly Lube - Club Car Part No.
  • Page 31: Lubrication - Electric Vehicles

    SERVICE PLACE* RECOMMENDED LUBRICANT Quarterly by Owner Brake shaft bearings Dry Moly Lube - Club Car Part No. 1012151 or Trained Technician Brake Linkage and Pivots Dry Moly Lube - Club Car Part No. 1012151 Accelerator pivots Dry Moly Lube - Club Car Part No. 1012151 Forward and reverse switch contacts WD-40®...
  • Page 32: Vehicle Capacities

    38 oz. (1.16 liters) Transmission 20 oz. (.61 liters) Drive Unit 22 oz. (.67 liters) 22 oz. (.67 liters) Gasoline Tank 7 gallons (26.5 liters) Tire Pressure 12-14 psi (83-96 kPa) 18-20 psi (124-138 kPa) WARNING • IF ANY PROBLEMS ARE FOUND DURING SCHEDULED INSPECTION OR SERVICE, DO NOT OPERATE THE VEHICLE UNTIL REPAIRS ARE MADE.
  • Page 33: Periodic Service - Gasoline Vehicles

    Tires Check for wear and damage. Transmission Check shift linkage for proper operation. Make sure all are in place (See Gasoline Vehicle Vehicle warning decals Feature Identification, in DS Owner’s Manual). Clean terminals and wash dirt from casing, check Battery electrolyte level (See Section 22).
  • Page 34 PERIODIC SERVICE SCHEDULE - GASOLINE VEHICLES REGULAR INTERVAL SERVICE Wash battery top with baking soda/water solution Battery (See Section 22). Check brake cables for damage; replace as required. Check for proper operation (See Performance Inspec- Brake System tion, Page 3-2). Check brake pedal free play. Adjust as necessary (See Section 6).
  • Page 35: Periodic Service - Electric Vehicles

    PERIODIC SERVICE SCHEDULE - GASOLINE VEHICLES REGULAR INTERVAL SERVICE Check for proper operation. Inspect belt and replace Torque Converter/Drive Belt as required (See Section 16). Check for cracks, wear, and glazing, replace if neces- Semi-annual Service by sary. Trained Mechanic Only...
  • Page 36 PERIODIC SERVICE SCHEDULE - ELECTRIC VEHICLES REGULAR INTERVAL SERVICE Batteries Charge batteries. Check for proper operation (See Performance Inspec- Brake System tion, Page 3-2). Adjust as necessary. Charger and Receptacle Check for damage and snug fit. Check for proper operation (See Section 6). Adjust as Park Brake necessary.
  • Page 37 PERIODIC SERVICE SCHEDULE - ELECTRIC VEHICLES REGULAR INTERVAL SERVICE Check specific gravity, electrolyte level, and on- Batteries charge voltage (See Section 22). Check for proper operation (See Performance Inspec- tion, Page 3-2). Check brake pedal free play. Clean, and adjust as necessary (See Section 6). Brake System Check brake shoes, replace if necessary.
  • Page 38 Page 4-10...
  • Page 39: Body And Trim

    • HOT! - DO NOT ATTEMPT TO SERVICE HOT MOTOR, RESISTORS, ENGINE, OR EXHAUST SYSTEM. FAILURE TO HEED THIS WARNING CAN RESULT IN SEVERE BURNS. • GASOLINE VEHICLE: TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE, DISCONNECT THE SPARK PLUG WIRE FROM THE PLUG.
  • Page 40: Front And Rear Body Repair

    1. Water sand the body. 2. Clean and dry the body thoroughly. 3. Apply a light coat of adhesion promoter (Club Car Part No. 1016985) to the affected area. CAUTION • DO NOT SPRAY ADHESION PROMOTER ON EXISTING CLEARCOAT. MASK BODY PANEL AROUND THE AREA TO BE SPRAYED, THEN REMOVE EXISTING CLEARCLOAT IN THE DAM- AGED AREA BEFORE APPLYING ADHESION PROMOTER.
  • Page 41 3. Apply a light coat of adhesion promoter to the damaged area and the surrounding surface. See CAU- TION on Page 5-2. 4. Using the Flexible Epoxy Kit (Club Car Part No. 1017295), mix enough resin and hardener (equal amounts) to completely fill in the damaged area (Figure 5-3). Spread the mixture over the damaged area with a putty knife or spreader, using ample pressure to eliminate air pockets (Figure 5-4).
  • Page 42: Seat

    7. Apply a light coat of adhesion promoter and let it air dry for 30 minutes. 8. Paint the repaired area with matching spray paint (available from Club Car). Hold the can about 12 to 14 inches (30-35 cm) from the repaired surface and coat with light, even strokes (Figure 5-8). Addi- tional coats may be required.
  • Page 43: Rear Body

    • HOT! - DO NOT ATTEMPT TO SERVICE HOT MOTOR, RESISTORS, ENGINE, OR EXHAUST SYSTEM. FAILURE TO HEED THIS WARNING CAN RESULT IN SEVERE BURNS. • GASOLINE VEHICLE: TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE, DISCONNECT THE SPARK PLUG WIRE FROM THE PLUG.
  • Page 44 - Disconnect the three wires from the rear of the charger receptacle (inside the battery compartment) (See Figure 5-12). The receptacle does not have to be removed from the body. • Gasoline vehicles - Remove four screws, hex nuts, and lock washers securing the Forward and Reverse Switch to the rear body.
  • Page 45 yyyyy yy yy yy yy yyyyy yyyyy FIGURE 5-10 FIGURE 5-11 CHARGER 6 GAUGE RED WIRE RECEPTACLE TO BATTERY - DISCONNECT AT BATTERY GREY WIRE FROM OBC NO. 10 BLACK WIRE TO OBC - GREY SENSE LEAD DISCONNECT WITH FUSE - AT RECEPTACLE DISCONNECT HERE FIGURE 5-12...
  • Page 46: Floormat

    • INSTALL THE MOUNTING PADS (ITEM 4, FIGURE 5-13) BETWEEN THE REAR BODY AND THE SEAT BACK ASSEMBLY. REAR BODY SOUND INSULATION - GASOLINE VEHICLES Removal Of Insulation 1. Remove the rear body as instructed on Pages 5-5 through 5-7.
  • Page 47: Accelerator And Brake Pedal Group

    In February of 1995 (Serial No. A9529 445799 and greater on electric vehicles, and Serial No. AG9529 445519 and greater on gasoline vehicles), a new accelerator/brake pedal group was introduced. Adjustment procedures for the older and later pedal groups differ significantly, so it is important to make sure that you use the correct procedure.
  • Page 48 Pedal Group Adjustment - Early 1995 Vehicles, Continued: WARNING • TO PROPERLY ADJUST BRAKE PEDAL AND CABLE ASSEMBLY, CHECK, AND ADJUST IF NEC- ESSARY, THE FOLLOWING ITEMS IN THE ORDER LISTED: - BRAKE PEDAL AND CABLE ADJUSTMENT. BEGINNING THIS PAGE. - ACCELERATOR ROD ADJUSTMENT.
  • Page 49 2.2. Using two wrenches, tighten the jam nuts on the brake equalizer rod (Figure 6-1). 3. ADJUST THE ACCELERATOR ROD (See page 6-5 for electric vehicles). • Adjust the Accelerator Rod - Early 1995 Gasoline Vehicles Only: DANGER • BEFORE SERVICING, TURN THE KEY SWITCH TO OFF AND PLACE THE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSITION.
  • Page 50 Adjust the Accelerator Rod - Early 1995 Gasoline Vehicles Only, Continued: CAUTION • AFTER ACCELERATOR ROD ADJUSTMENT, MAKE SURE THAT APPROXIMATELY THE SAME NUMBER OF THREADS IS EXPOSED AT EACH END OF THE ROD. • IF THE LEVER ON THE LIMIT SWITCH IN THE ELECTRICAL BOX IS BENT, REPLACE THE LIMIT SWITCH.
  • Page 51 • Adjust the Accelerator Rod - Early 1995 V-Glide 36 Volt Electric, PowerDrive System 48 Electric, and PowerDrive Plus Vehicles: DANGER • BEFORE SERVICING, TURN THE KEY SWITCH TO OFF AND PLACE THE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSITION. •...
  • Page 52 ERWISE THE PARK BRAKE AND/OR WIPER SWITCH MAY NOT OPERATE PROPERLY. yyyyy • Adjust the Accelerator Pedal Stop - Early 1995 Gasoline Vehicles: 4.1. Disconnect the accelerator rod ball joint (11) at the accelerator pedal (1) (Figure 6-5, Page 6-3).
  • Page 53 NOTE • AS ACCELERATOR PEDAL DISTANCE FROM THE FLOORBOARD IS INCREASED, THE BRAKE PEDAL RATCHET AND PAWL GAP IS DECREASED, AND AS THE PEDAL DISTANCE IS DECREASED, THE RATCHET AND PAWL GAP IS INCREASED. IF THE ACCELERATOR PEDAL DISTANCE FROM THE FLOORMAT IS ADJUSTED, CHECK AND ADJUST THE RATCHET AND PAWL GAP AS INSTRUCTED IN SECTION 5.
  • Page 54 ORDER TO ACHIEVE THE PROPER ADJUSTMENTS. 5. ADJUST THE PARK BRAKE (See page 6-9 for electric vehicles). • Adjust the Park Brake - Early 1995 Gasoline Vehicles: 5.1. Inspect the park brake pawl and latch for excessive wear, grooves, cracks, or chipping. If either the pawl or latch is damaged, both must be replaced.
  • Page 55: Pedal Group Disassembly And Assembly - Early 1995 Vehicles

    RATCHET (B) TOOTH LENGTH LOCKED POSITION .030" - .125" (.08 -.32 cm) MAKE SURE PAWL (A) ENGAGES AT LEAST 75% USE FEELER GAUGE OF RACHET TOOTH LENGTH (B) TO CHECK GAP BOTTOM VIEW FIGURE 6-11 FIGURE 6-12 5.4. Using a 1/2” wrench, adjust the accelerator stop until there is a .030” to .125” (0.8 to 3.2 mm) gap between the brake latch and the pawl.
  • Page 56 Installing the Brake Pedal Assembly - Early 1995 Vehicles, Continued: FIGURE 6-13 2. Attach the equalizer rod (26) to the brake pedal weldment assembly (6) as shown (Figure 6-13). 3. Position and attach the brake pedal assembly and mounting blocks (23) to the vehicle frame as shown. Tighten the bolts and nuts to 40-60 in.lbs.
  • Page 57 NOTE • BRAKE PEDAL FREE PLAY IS THE DISTANCE THE BRAKE PEDAL CAN BE DEPRESSED BEFORE THE BRAKE ACTUATOR ARM MOVES. REMOVING THE PARK BRAKE ASSEMBLY 1. To remove the park brake rod and pawl assembly (9 through 13 and 32), remove the push-on nut (11) and disconnect the ball joint sleeve (13) from the park brake pedal (1).
  • Page 58 FIGURE 6-16 REMOVING THE ACCELERATOR PEDAL ASSEMBLY - EARLY 1995 VEHICLES • Removing the Accelerator Pedal Assembly - Early 1995 Gasoline Vehicles: 1. Remove the accelerator rod by sliding back the ball joint sleeve and disconnecting the ball joint (11) from the ball joint stud (6) (Figure 6-5, Page 6-3).
  • Page 59: Pedal Group Adjustment - Late 1995 And 1996 Vehicles

    bearing bracket (21) (Figure 6-5, Page 6-3). 3. Secure the bearing brackets to the I-beam frame using the existing four 1/4 - 20 hex head bolts (19) and nuts (18). Tighten the bolts and nuts to 70-80 in.lbs. (8/9 N-m) (Figure 6-5, Page 6-3). 4.
  • Page 60 WARNING • ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON- NECTIONS. GASOLINE VEHICLES ONLY: • TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE, ALWAYS BEFORE SERVICING: - DISCONNECT BATTERY CABLES, NEGATIVE (-) FIRST. - DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG.
  • Page 61 LEVER MUST ALSO BE ADJUSTED IF THE RATCHET/PAWL GAP IS ADJUSTED (SEE STEP 4, PAGE 6-19). • ON DS V-GLIDE 36 VOLT ELECTRIC AND ON DS GASOLINE POWERED VEHICLES, THE ACCELERATOR ROD ADJUSTMENT MUST ALSO BE CHECKED IF THE RATCHET/PAWL GAP IS ADJUSTED (SEE STEP 4, PAGE 6-17, OR STEP 4, PAGE 6-18).
  • Page 62 3.1. Using a 1/2” socket and 1/2” wrench, loosen the nut and bolt (Figure 6-24) securing the accelera- tor pedal to the pivot plate. Clamp the accelerator pedal adjustment tool (Club Car Part No. 1018710-01) to the accelerator pedal, with the end marked accelerator pedal height toward the floorboard, then depress the accelerator pedal until the end of the tool rests against the floor-...
  • Page 63 4. ADJUST THE ACCELERATOR ROD (See page 6-18 for V-Glide 36 volt electric vehicles, or page 16-19 for PowerDrive System 48 and PowerDrive Plus 48 volt vehicles). • Adjust the Accelerator Rod - Gasoline Vehicles Only: DANGER • BEFORE SERVICING, TURN THE KEY SWITCH TO OFF AND PLACE THE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSITION.
  • Page 64 Adjust the Accelerator Rod - Gasoline Vehicles Only, Continued: NOTE • AFTER THE PEDAL GROUP AND ACCELERATOR ROD ARE ADJUSTED, THE FINAL GOV- ERNED ENGINE RPM SHOULD BE SET PER SPECIFICATIONS IN SECTION 13, PAGE 13-50. 4.5. If the events above occur as they should, hold the ball joint at each end of the accelerator rod with pliers and tighten the accelerator rod jam nut against it 4.6.
  • Page 65 • PowerDrive System 48 and PowerDrive Plus Vehicles Only - Adjust the Actuator Lever (There is no accelerator rod on PowerDrive vehicles): 4.1. Connect the Calibration Test Module (Club Car Part No. 1018871-01) (Figure 6-28, Page 6-20) to the vehicle.
  • Page 66 SPEED SENSOR TEST: SET MODE SWITCH TO "SSAM", CONNECT TEST SOCKET TO MOTOR SPEED SENSOR PLUG, ROTATE MOTOR. L.E.D. SHOULD PULSE ON AND OFF INDICATING SPEED SENSOR IS FUNCTIONAL. BUTTON SEE OPERATING INSTRUCTIONS FOR MORE DETAIL POWER Club Car MODE SSAM FIGURE 6-28 FIGURE 6-29 4 5/8"...
  • Page 67 4.4. Using a 7/16” deep well socket, slightly loosen the bolt (9) (Figure 6-32) attaching the actuator lever to the adjustment bracket. 4.5. Rotate the actuator lever (17) on the pivot rod weldment (6) (Figure 6-35, Page 6-22) counter- clockwise until the red LED on the test module goes out (limit switch clicks off). Then slowly rotate the actuator lever clockwise until the red LED is illuminated again (limit switch clicks on).
  • Page 68 Adjust the Actuator Lever - PowerDrive System 48 and PowerDrive Plus Vehicles, Continued: 4.12. Disconnect the Calibration Test Module from the vehicle and reconnect the three-wire connector (from the potentiometer) to the wire harness. Reconnect the green/white wire to the Forward and Reverse Limit Switch No.
  • Page 69: Pedal Group Disassembly And Assembly - Late 1995 And 1996 Vehicles

    1. Make sure the key switch is off and that the Forward and Reverse Switch is in neutral, then disconnect the battery or batteries as shown (Figure 12-1, Page 12-2 for gasoline vehicles, or Figure 22-5 or 22-6, Page 22-5 for electric vehicles). See CAUTION below.
  • Page 70 • THE PROCEDURE FOR INSTALLING THE PARK BRAKE ASSEMBLY IS THE SAME AS IT IS FOR EARLY 1995 VEHICLES. REMOVING THE ACCELERATOR PEDAL ASSEMBLY DS V-Glide Electric Vehicles (Serial Number 9529 445799 and Later) and DS Gasoline Vehicles (Serial Number 9529 445519 and Later). (For PowerDrive System 48 and PowerDrive Plus vehicles, see page 6-27).
  • Page 71 (23) (Figure 6-27, Page 6-19). See NOTE below. NOTE • ON GASOLINE VEHICLES SERIAL NO. AG 9633-517738 AND LATER, ITEMS (15) AND (17) ARE DELETED AND ITEM (22) IS LONGER. 12. Pull accelerator pedal (1) out of vehicle from the top side of the floorboard (Figure 6-27, Page 6-19).
  • Page 72 (Figure 6-27, Page 6-19). Tighten the nut to 16-20 ft.lbs. (22/27 N-m). See NOTE below. NOTE • ON GASOLINE VEHICLES SERIAL NO. AG 9633-517738 AND LATER, ITEMS (15) AND (17) ARE DELETED AND ITEM (22) IS LONGER. 11. Install the accelerator rod assembly (19, 20, and 21) (Figure 6-27, Page 6-19).
  • Page 73 REMOVING THE ACCELERATOR PEDAL ASSEMBLY DS PowerDrive System 48 Vehicles and DS PowerDrive Plus Vehicles (Serial Number A9529 445799 and Later) 1. Make sure the key switch is off and that the Forward and Reverse Switch is in neutral, then disconnect the batteries as shown (Figure 22-6, Page 22-5).
  • Page 74 INSTALLING THE ACCELERATOR PEDAL ASSEMBLY DS PowerDrive System 48 Vehicles and DS PowerDrive Plus Vehicles (Serial Number A9529 445799 and Later) 1. Position the accelerator pivot rod support (22) and the potentiometer assembly (21) on the vehicle frame and install the four hex head cap screws (23), flat washers (8), and lock nuts (11). Tighten the nuts with fingers only at this time (Figure 6-35, Page 6-22).
  • Page 75 8. Slide the pivot rod toward the passenger side of the vehicle until approximately one-half of the length of the pivot rod splines is exposed (Figure 6-35, Page 6-22). 9. Depress the brake pedal slightly, and with the park brake ratchet oriented so that the tip of the ratchet is pointed toward the rear of vehicle, slide the ratchet onto the pivot rod (do not slide the ratchet onto the pivot rod splines).
  • Page 76 Page 6-30...
  • Page 77: Wheel Brake Assemblies

    SECTION 7 - WHEEL BRAKE ASSEMBLIES All 1995 and 1996 model DS Golf Cars, both gasoline and electric, are equipped with self-adjusting, mechanically expanding shoe drum brakes on each rear wheel. WARNING • ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL REPAIR.
  • Page 78 TYPICAL 4 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES SELF-ADJUSTING WHEEL BRAKE ASSEMBLY FIGURE 7-1 Page 7-2...
  • Page 79: Removal Of Brake Shoes And Cleaning Of Wheel Brake Assemblies

    REMOVAL OF BRAKE SHOES AND CLEANING OF WHEEL BRAKE ASSEMBLIES REMOVE THE BRAKE SHOES AND CLEAN THE BRAKE ASSEMBLY WARNING • SOME BRAKE SHOES CONTAIN ASBESTOS FIBER AND ASBESTOS DUST IS CREATED WHEN THESE BRAKE MECHANISMS ARE HANDLED. WEAR APPROVED EYE AND RESPIRATORY PROTECTION WHEN DISASSEMBLING AND CLEANING BRAKE MECHANISMS.
  • Page 80 Removal of Brake Shoes and Cleaning of Wheel Brake Assemblies, Continued: CAUTION • AFTER INSTALLING AXLE SHAFT, CLEAN ANY RESIDUAL OIL FROM THE EXPOSED END OF yy yy THE AXLE SHAFT AND FROM THE OIL SEAL AREA. 4.1. Using snap ring pliers, remove the axle retaining ring (1) (Figure 7-3, Page 7-3). 4.2.
  • Page 81 LUBRICATE SLIDE (1) AND SLIDE PLATE (2) WITH DRY GRAPHITE LUBRICANT. THEN WORK THE SLIDE BACK AND FORTH FIGURE 7-6 FIGURE 7-7 USE A BRUSH TO APPLY A BOSSES LIBERAL AMOUNT OF WHITE LITHIUM NLGI #2 GREASE TO THE ENDS OF THE BRAKE SHOES AND IN THE SHOE MOUNTING SLOTS AS SHOWN.
  • Page 82: Installing The Brake Shoes

    Removal of Brake Shoes and Cleaning of Wheel Brake Assemblies, Continued: 12. Use a brush to apply a liberal amount of white lithium NLGI #2 grease (Dow Corning BR2-Plus or equivalent) to the brake adjuster assembly, adjuster wheel shoe slots, and the shaft of the adjuster wheel as shown (Figure 7-10, Page 7-5).
  • Page 83: Brake Assembly

    2. Install the shoe retainer clips, using pliers to compress the clip while turning the clip retaining tab into position (Figure 7-12). 3. Attach the springs onto the trailing shoe already installed. Then hold the leading shoe next to the trail- ing shoe, correctly oriented, and attach the springs to it (Figure 7-13).
  • Page 84 5. Remove cotter pin (13) and clevis pin (12) from brake cable (Figure 7-1, Page 7-2). 6. Remove 4 bolts (11) (Club Car Part No. 1014153) and lock nuts (10) (Club Car Part No. 1013924) that mount the brake assembly to the transaxle.
  • Page 85: Steering And Front Suspension

    USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE. • ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON- NECTIONS. GASOLINE VEHICLES ONLY: • TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE, ALWAYS BEFORE SERVICING: - DISCONNECT BATTERY CABLES, NEGATIVE (-) FIRST.
  • Page 86: Steering Wheel

    3. Loosen the steering wheel nut (27) and back it off approximately 1/4” (6 mm). Do not remove it (Figure 8-2). 4. Pull the steering wheel until it breaks free from the shaft splines (Club Car recommends using a steer- ing wheel puller) (Figure 8-1).
  • Page 87 3.4. Pull center dash out approximately one inch from the frame and then bend the top right corner of the center dash inward while pulling the top of the panel out and down. NOTE • BENDING THE TOP RIGHT CORNER OF THE CENTER DASH INWARD WHILE REMOVING IT WILL PREVENT THE CONTACTS ON THE REAR OF THE KEY SWITCH FROM TOUCHING THE METAL FRAME AROUND THE DASH.
  • Page 88 Steering Column Disassembly, Continued: 8. Insert a flat blade screwdriver between the bottom of the outer race of the bearing and the bottom lip of the bearing seat (18) and remove the bearing (17) (Figure 8-2 CAUTION • DO NOT DAMAGE THE BEARING OR BEARING SEAT WHILE REMOVING THE BEARING. yy yy TYPICAL 2 PLACES...
  • Page 89 2. Press the bearing (17) all the way into the bearing seat (18) using a steering column bearing press tool (Club Car Part No. 1014264) or a metal tube approximately six inches (15-24 cm) long with a maximum outer diameter of 1-3/16 inches (3.3 centimeters) and a minimum inside diameter of 7/8 of an inch (2.2 centimeters).
  • Page 90: Steering Adjustment

    Steering Column Installation, Continued: 3. Position the steering column assembly in the vehicle while inserting the steering column shaft into the upper universal joint. The flat portion of the steering shaft spline must be aligned with the bolt hole in the universal joint before sliding the spline into the universal joint.
  • Page 91 CAPACITY. DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION. ALWAYS USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE. GASOLINE VEHICLES ONLY: • TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE, ALWAYS BEFORE SERVICING: - DISCONNECT BATTERY CABLES, NEGATIVE (-) FIRST.
  • Page 92 Rack and Pinion Removal, Continued: TYPICAL 3 PLACES TYPICAL 3 PLACES FIGURE 8-7 1. Remove the front body as instructed in Section 5. 2. Remove the cotter pin (14) and ball joint retaining nut (15) (Figure 8-7). 3. Using a ball joint removal tool, remove the ball joint (13) (Figure 8-7) from the spindle assembly (See Figures 8-5 and 8-6, Page 8-7).
  • Page 93 RACK AND PINION DISASSEMBLY (SEE NOTE BELOW) NOTE • DURING THE 1996 MODEL YEAR, CLUB CAR INCORPORATED A NEW RACK AND PINION ASSEMBLY. FOR DS GASOLINE VEHICLES PRIOR TO SERIAL NO. AG9633-517735, AND FOR DS ELECTRIC VEHICLES PRIOR TO SERIAL NO. A9640-533437, FOLLOW THE INSTRUCTIONS BELOW.
  • Page 94 RACK AND PINION ASSEMBLY (SEE NOTE BELOW) NOTE • THESE ASSEMBLY INSTRUCTIONS FOR THE RACK AND PINION PERTAIN TO DS GASOLINE VEHICLES PRIOR TO SERIAL NUMBER AG9633-517735, AND TO DS ELECTRIC VEHICLES PRIOR TO SERIAL NUMBER A9640-533437. FOR LATER VEHICLES, GO TO PAGE 8-15.
  • Page 95 2. Install the washer (33), a new tie rod lock washer (34), and a new ball joint (10). Tighten using two wrenches, one on the ball joint and one on the rack (9). Tighten the ball joint to 50-55 ft.lbs. (68/75 N-m) (Figure 8-7, Page 8-8).
  • Page 96 Rack and Pinion Assembly, Continued: PRESS RAM BUSHING 15/16 DEEP WELL SOCKET STEERING GEAR DUST SEAL HOUSING FIGURE 8-14 FIGURE 8-15 9. Install the internal snap ring (29) (Figure 8-7, Page 8-8). 10. Using a 15/16 deep well socket to apply pressure evenly, lightly tap in a new dust seal (30) (Figure 8-7, Page 8-8) (See Figure 8-15).
  • Page 97 RACK AND PINION DISASSEMBLY (SEE NOTE BELOW) NOTE • THESE INSTRUCTIONS FOR RACK AND PINION DISASSEMBLY PERTAIN TO GASOLINE VEHI- CLES SERIAL NUMBER AG9633-517735 AND LATER AND TO ELECTRIC VEHICLES SERIAL NUMBER A9640-533437 AND LATER. FOR EARLIER VEHICLES, GO TO PAGE 8-9.
  • Page 98 Rack and Pinion Disassembly, Continued: TYPICAL 3 PLACES TYPICAL 3 PLACES FIGURE 8-17 8. Remove the dust seal (12) (Figure 8-17) with a cotter key puller (See Figure 8-8, Page 8-10). NOTE • IF THE DUST SEAL (12) IS REMOVED, REPLACE WITH A NEW ONE. 9.
  • Page 99 RACK AND PINION ASSEMBLY (SEE NOTE BELOW) NOTE • THESE ASSEMBLY INSTRUCTIONS FOR THE RACK AND PINION PERTAIN TO DS GASOLINE VEHICLES SERIAL NO. AG9633-517735 AND LATER, AND DS ELECTRIC VEHICLES SERIAL NUMBER A9640-533437 AND LATER. FOR EARLIER VEHICLES, GO TO PAGE 8-10.
  • Page 100: Tie Rod And Drag Link

    Rack and Pinion Assembly, Continued: 11. Install the rack guide (13), pressure spring (14), and screw (16). The screw should be threaded in until tight and then backed off 1/8 of a turn. Install the lock nut (15) on the screw and tighten it to 29 ft.lbs. (39.3 N-m) (Figure 8-17, Page 8-14).
  • Page 101 ETC. BEFORE SERVICING VEHICLE. • ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON- NECTIONS. GASOLINE VEHICLES ONLY: • TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE; ALWAYS, BEFORE SERVICING: - DISCONNECT BATTERY CABLES, NEGATIVE (-) FIRST. - DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG.
  • Page 102: Front Suspension

    Tie Rod and Drag Link Installation, Continued: 3. Thread the drag link rod (28) all the way onto the threaded stud of the inner ball joint assembly (right hand threads) (Figure 8-17, Page 8-14). 4. Thread the ball joint (23) into the drag link rod (28) (left hand threads) to full thread depth (Figure 8-17). 5.
  • Page 103 PROPER CAMBER Club Car LOOSEN 4 BOLTS (30) ADJUSTMENT LOOSEN HEX NUT (8) ON ECCENTRIC EQUAL SPACE ECCENTRIC BETWEEN TIRES AND ADJUSTER (7) FRAMING SQUARES IMPROPER USE 9/32 DEEP WELL CAMBER SOCKET TO ADJUST Club Car ADJUSTMENT ECCENTRIC Club Car...
  • Page 104: Front Suspension Components

    ETC. BEFORE SERVICING VEHICLE. • ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON- NECTIONS. GASOLINE VEHICLES ONLY: • TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE; ALWAYS, BEFORE SERVICING: - DISCONNECT BATTERY CABLES, NEGATIVE (-) FIRST. - DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG.
  • Page 105 TYPICAL 4 PLACES TYPICAL 3 PLACES TYPICAL 4 PLACES TYPICAL 3 PLACES FIGURE 8-22 WARNING • LIFT ONLY ONE END OF A 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.
  • Page 106 Tapered Leaf Spring Removal, Continued: 4. Remove the four bolts (30), four nuts (32), four lock washers (31), and bottom spring plate (29) (Figure 8-23). 5. Remove tapered leaf spring (6) (Figure 8-23). 6. Check the condition of the bushings (27) and spacers (28) (Figure 8-23). Replace any that are worn or damaged.
  • Page 107 TYPICAL 4 PLACES PASSENGER SIDE ONLY DRIVER TYPICAL SIDE ONLY 4 PLACES TYPICAL 4 PLACES FIGURE 8-23 4. Install the steering spindle on the king pin. Then install the thrust washer (19), A-Plate clevis (16), lock washer (18), and nut (17). Tighten the nut to 35-45 ft.lbs. (47/61 N-m) (Figure 8-23). 5.
  • Page 108: Front Wheel Bearings And Hubs

    DELTA A-PLATE REMOVAL 1. Remove the wheel and tire. 2. Remove the bolts (10 and 24), A-Plate straps (14), and nuts (5) (Figure 8-22, Page 8-21). 3. Remove the lower shock absorber mounting nut (9), then slide the shock absorber free of the Delta A- Plate (Figure 8-22, Page 8-21).
  • Page 109 FIGURE 8-24 3. Remove the seal (6) and the bearings (5) from the hub (Figure 8-24). 4. Inspect the bearing cups (7). If they are worn or pitted, remove the cups by inserting a drift punch from the opposite end of the hub and tapping lightly around them (Figure 8-24). 5.
  • Page 110 Page 8-26...
  • Page 111: Lubrication

    SECTION 9 - TRANSAXLE LUBRICATION There are two plugs located on the lower half of the transaxle housing. The upper one, when the transaxle is in a horizontal position, is used as a lubricant level indicator. The lubricant level should be even with the bot- tom of the hole.
  • Page 112: Axle Shaft

    CAPACITY. DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION. ALWAYS USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE. GASOLINE VEHICLES ONLY: • TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE, ALWAYS BEFORE SERVICING: - DISCONNECT BATTERY CABLES, NEGATIVE (-) FIRST.
  • Page 113: Axle Bearing

    FIGURE 9-4 AXLE BEARING Removing the Axle Bearing 1. Place a bearing puller wedge attachment (Club Car Part No. 1012812) on the axle shaft between the wheel mounting flange and the bearing. CAUTION • DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE AXLE SHAFT.
  • Page 114 Removing The Axle Bearing, Continued: 2. Press the bearing (5) and collar (4) (Figure 9-1, Page 9-1) off together (See Figure 9-5). NOTE • IT MAY BE NECESSARY TO HEAT THE COLLAR TO REMOVE IT. BEARING PULLER WEDGE ATTACHMENT PRESS RAM AXLE SEAL TOOL AXLE SEAL...
  • Page 115: Removing The Transaxle

    2. Place a new seal (17) (Figure 9-1) in the axle tube with the 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 (Fig- ure 9-6).
  • Page 116 Removing the Transaxle - DS Gasoline, Continued: 2. Disconnect, at the starter, the braided ground wire from the starter to the frame. 3. Remove the rear wheels, then thread one lug nut onto a stud on each rear hub. This will keep the brake drums on the hubs.
  • Page 117 PLACE JACK UNDER INNER FRAME REAR CROSS-MEMBER SIDE VIEW PULL COVER BACK TO REMOVE TOP VIEW THROUGH SERVICE OPENING FIGURE 9-9 FIGURE 9-10 SIDE VIEW TRANSMISSION SUPPORT STRAP REMOVE BOLTS, THEN ROTATE SHACKLES UP AND AWAY FROM SPRING FIGURE 9-11 FIGURE 9-12 14.
  • Page 118 REMOVING THE TRANSAXLE - DS ELECTRIC WARNING • ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE. WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES. • TURN KEY SWITCH OFF, PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI- TION, AND REMOVE KEY PRIOR TO SERVICING.
  • Page 119 REMOVE BOLTS, THEN ROTATE SHACKLES UP AND AWAY FROM SPRING DISCONNECT SHOCK ABSORBERS FROM LOWER MOUNTS FIGURE 9-15 FIGURE 9-16 MOTOR MOUNTING REST LEAF SPRINGS ON FLOOR BOLTS THEN REMOVE "U" BOLTS INPUT PINION GEAR INTERMEDIATE DIFFERENTIAL GEAR ASSEMBLY CAGE GEAR FIGURE 9-17 FIGURE 9-18 5.
  • Page 120: Disassembly, Inspection, And Assembly Of The Transaxle

    Removing the Transaxle - DS Electric, Continued: 12. Carefully lift each end of the transaxle off of its positioning pin (on the leaf spring) and slide the trans- axle to the rear and out of the vehicle. 13. Drain the lubricant from the transaxle as instructed on Page 9-1. 14.
  • Page 121 5. Use a bearing puller or arbor press to remove bearings (18) (Figure 9-1, Page 9-1) from the input pin- ion gear. If the oil seal (10) (Figure 9-1) is damaged, replace it. See CAUTION below. CAUTION • DO NOT REUSE BEARINGS AFTER REMOVING THEM. REPLACE THEM WITH NEW ONES. 6.
  • Page 122 Disassembly and Inspection of the Transaxle, Continued: SIDE THRUST GEAR WASHER DIFFERENTIAL PUSH LEFT DIFFERENTIAL DIFFERENTIAL GEAR PIN THROUGH CASE DIFFERENTIAL GEAR CASE FIGURE 9-23 FIGURE 9-24 9.6. Remove the idler gears and thrust washers (36 and 35) (Figure 9-1, Page 9-1). 9.7.
  • Page 123 11. Apply grease to the lip of the new oil seal (10) (Figure 9-1, Page 9-1) and install the seal using a tran- saxle pinion seal tool (Club Car Part No. 1014161). The lip of the oil seal should face to the inside of the transaxle housing.
  • Page 124: Shimming The Transaxle

    (14) (Figure 9-1) on the differential cage (32) (Figure 9-1) (See Figure 9-25). 3. Use the chart below to determine whether shimming is required and, if so, how many shims (Club Car Part No. 1013781) should be used.
  • Page 125: Installation Of The Transaxle

    INSTALLATION OF THE TRANSAXLE INSTALLING THE TRANSAXLE - DS GASOLINE VEHICLE 1. Install the transmission and Forward and Reverse shifter cable bracket on the transaxle as instructed in Section 17, Page 17-23 in this manual. 2. Install the driven clutch as instructed in Section 16, Page 16-17 in this manual.
  • Page 126 Installing the Transaxle - DS Electric Vehicle, Continued: 7. Insert bolts through the spring shackles and bushings in the leaf spring eyes. Secure them with lock nuts. 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.
  • Page 127: Wheels And Tires

    GENERAL INFORMATION Maximum tire life and good vehicle handling qualities are directly related to proper wheel and tire care. • Keep tires inflated to 12-14 psi (83-96 kPa) for gasoline vehicles; 18-20 psi (124-138 kPa) for electric vehicles. • Keep axle nuts and wheel mounting nuts properly torqued.
  • Page 128: Wheel Removal

    WHEEL REMOVAL 1. Slightly loosen the wheel rim mounting nuts on the wheel to be removed. 2. Raise the end of the vehicle from which the wheel is to be removed. Make sure that the wheels are off of the ground. See WARNING below. WARNING •...
  • Page 129: Removing The Tire From The Rim

    REMOVING THE TIRE FROM THE RIM NOTE • TIRE MUST BE REMOVED OR INSTALLED FROM THE VALVE STEM SIDE OF THE RIM. 1. Remove the tire and wheel assembly from the vehicle as instructed above. 2. Remove the valve cap and valve core and allow air to escape from the tire. 3.
  • Page 130 Installing The Tire On The Rim, Continued: 2. Where the tire beads seat, clean the wheel rim with a wire brush. NOTE • BECAUSE TUBELESS TIRES REQUIRE A PERFECT SEAL IN ORDER TO SEAT, CLEANING OF THE TIRE AND RIM IS VERY IMPORTANT. 3.
  • Page 131: Troubleshooting The Gasoline Vehicle

    SECTION 11 - TROUBLESHOOTING THE GASOLINE VEHICLE Your Club Car DS vehicle will operate for a longer period of time without repairs if it is given proper care and preventive maintenance. The following check list will be helpful in identifying operating difficulties should they occur.
  • Page 132 SYMPTOM POSSIBLE CAUSES REFER TO Engine does not start Igniter failed Section 12, Gasoline Vehicle Electrical easily, continued: System Low cylinder compression Section 13, Engine Water or dirt in the fuel Section 14, Fuel System system and/or carburetor; dirty or clogged fuel filter...
  • Page 133 Muffler or exhaust pipe restricted with Section 15, Exhaust System carbon or other substance Igniter failed Section 12, Gasoline Vehicle Electrical System Air filter is dirty or clogged Section 14, Fuel System Governor is improperly adjusted Section 14, Fuel System...
  • Page 134 SYMPTOM POSSIBLE CAUSES REFER TO Starter fails to operate, continued: Starter solenoid failed Section 12, Gasoline Vehicle Electrical System - Starter circuit Accelerator limit switch failed Section 12, Gasoline Vehicle Electrical System - Starter circuit Key switch failed Section 12, Gasoline Vehicle...
  • Page 135 SYMPTOM POSSIBLE CAUSES REFER TO Damaged starter/generator pulley Section 12, Gasoline Vehicle Excessive vehicle Electrical System - vibration, continued: Starter/generator Misaligned clutches Section 16, Torque Converter RPM setting is incorrect Section 14, Fuel System Drive belt is worn, cracked, glazed, or...
  • Page 136 Page 11-6...
  • Page 137 SECTION 12 - ELECTRICAL SYSTEM GASOLINE VEHICLES DANGER • GASOLINE VAPORS - FLAMMABLE - DO NOT SMOKE! KEEP SPARKS, FLAMES, CIGA- RETTES AWAY. TOOLS, WIRES AND METAL OBJECTS CAN CAUSE SPARKS WHEN “SHORTED” ACROSS A BATTERY. INSULATED TOOLS SHOULD BE USED. EXTREME CARE SHOULD BE TAKEN WHEN DISCONNECTING OR CONNECTING BATTERY.
  • Page 138: Electrical System - Gasoline Vehicle

    BATTERY CABLES BEFORE WORKING ON VEHICLE FIGURE 12-1 The electrical system on the DS Gasoline is a 12 volt DC negative ground to frame system. The electrical system consists of seven readily-identifiable circuits. They are: • Starter Circuit • Generator Circuit •...
  • Page 139 The starter circuit consists of a twelve-volt battery, fuse, key switch, accelerator starter limit switch, neutral lock-out limit switch, solenoid, starter, and connecting wires. The battery is the source of power for the system. The fuse provides protection to the solenoid activating cir- cuit.
  • Page 140 FIGURE 12-3 THE GENERATOR CIRCUIT (FIGURE 12-4) The generator circuit consists of the starter/generator, voltage regulator, solenoid, the battery, and connect- ing wires. When battery power is first supplied to the starter/generator, the starter/generator turns the engine at low RPM (approx. 700). Once the engine starts running, it then drives the starter/generator. At any engine RPM over 1215 (3000 starter/generator RPM), the starter/generator functions as a generator, supplying charging current to the battery.
  • Page 141 SPARK PLUG SPARK PLUG RPM LIMITER RPM LIMITER IGNITER IGNITION COIL IGNITION COIL WITH IGNITER BULLET CONNECTOR ENGINE KILL ENGINE KILL WIRE WIRE BULLET BULLET CONNECTOR CONNECTOR FIGURE 12-5 FIGURE 12-6 ENGINE KILL CIRCUIT (FIGURE 12-7) The exciter coil in the ignition coil supplies electrical power for the spark plug, therefore the proper way to stop the engine is to run this electrical power to ground, by-passing the spark plug.
  • Page 142 LOW OIL WARNING CIRCUIT (FIGURE 12-9) (M-) KEY SWITCH FIGURE 12-8 FIGURE 12-9 The low oil warning circuit consists of an oil sending unit in the engine, a dash mounted oil light, and connect- ing wires. The light picks up power from the key switch when the key switch is turned to the ON position. When the oil level in the crankcase is low, the oil sending unit closes the circuit to the ground and illuminates the oil light.
  • Page 143: Circuit Testing

    FIGURE 12-11 FIGURE 12-12 CIRCUIT TESTING DANGER • DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTI- LATION. ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS, DEADLY POI- SON. 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 AND MECHANICAL REPAIR.
  • Page 144 Testing the Vehicle Battery, Continued: 4. Place the red (+) probe of a multimeter, set at Volts - DC, 20 volt range, on the positive (+) post and place the black (-) probe on the negative (-) post of the battery and take a voltage reading. If it shows less than 12.4 volts, or if the lowest specific gravity reading from Step 1 is less than 1.225, recharge the battery.
  • Page 145 DANGER • DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTI- LATION. ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS, DEADLY POI- SON. WARNING • WHEN MAKING ELECTRICAL TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION.
  • Page 146 Circuit Testing, Continued: DANGER • DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTI- LATION. ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS, DEADLY POI- SON. WARNING • WHEN MAKING ELECTRICAL TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION.
  • Page 147 ENGINE WILL NOT STOP RUNNING WHEN KEY SWITCH IS IN OFF POSITION CHECK KEY SWITCH (TEST PROCEDURE 17) INCORRECT CORRECT CONTINUITY READING CONTINUITY READING REPLACE KEY SWITCH CHECK CONNECTIONS OF CIRCUIT WIRING WIRES INCORRECTLY WIRES CORRECTLY CONNECTED CONNECTED CONNECT WIRES CORRECTLY CHECK CONTINUITY OF CIRCUIT WIRES (TEST PROCEDURE 8)
  • Page 148 DANGER • DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTI- LATION. ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS, DEADLY POI- SON. WARNING • WHEN MAKING ELECTRICAL TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION.
  • Page 149 Use the chart on page 12-14 (Figure 12-19) as a starting point for troubleshooting the neutral lock-out cir- cuit. See DANGER below and WARNING at the top of page 12-14. DANGER • DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTI- LATION. ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS, DEADLY POI- SON.
  • Page 150: Test Procedures

    Circuit Testing, Continued: WARNING • WHEN MAKING ELECTRICAL TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. - REMOVE THE KEY. - PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL. - DISCONNECT THE BATTERY AS SHOWN (FIGURE 12-1, PAGE 12-2). •...
  • Page 151 1. Place the neutral lock-out cam in the SERVICE position, put the forward and reverse lever in the NEU- TRAL position, and chock the wheels. 2. Check that the wires are connected correctly and are tight. If they are not, rewire or tighten as neces- sary.
  • Page 152 Test Procedure 3 - Ground Straps, Continued: YELLOW BLUE DATA HOLD AC/DC 500V MAX 250V MAX AC V DC V DATA HOLD WHITE / AC/DC 500V MAX 250V MAX WHITE BLACK AC V DC V PLACE BLACK (-) PROBE ON FRAME KEY SWITCH DISCONNECT THE 6 GAUGE BLACK WIRE FROM THE BATTERY.
  • Page 153 Test Procedure 5 - Solenoid: 1. Place the neutral lock-out cam in the SERVICE position, put the forward and reverse lever in the NEU- TRAL position, and chock the wheels. 2. Remove the electrical component box cover. 3. Check that the wires are connected correctly and are tight. If they are not, rewire or tighten as neces- sary.
  • Page 154 Test Procedure 5, Continued: SOLENOID SOLENOID DATA HOLD AC/DC 500V MAX 250V MAX AC V DATA HOLD DC V AC/DC 500V MAX 250V MAX AC V DC V ELECTRICAL COMPONENT ELECTRICAL FRAME COMPONENT BOX FIGURE 12-23 FIGURE 12-24 Test Procedure 6 - Cam-Activated Neutral Lock-out Limit Switch: This switch is located on the forward and reverse switch assembly.
  • Page 155 2. Check for proper wiring and tight connections. 3. Place the red (+) probe of the multimeter on the common (COM) terminal of the limit switch. Place the black (-) probe on the normally open (NO) terminal of the limit switch. Without the lever depressed, the reading should be no continuity.
  • Page 156 Test Procedure 9 - Starter/Generator (Generator Function) (Figure 12-27): DANGER • DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTI- LATION. ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS, DEADLY POI- SON.
  • Page 157 4. Reconnect the yellow wire to the (DF) terminal on the starter/generator. Test Procedure 10 - Voltage Regulator: DANGER • DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTI- LATION. ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS, DEADLY POI- SON.
  • Page 158 Test Procedure 11, Continued: 1. Place the neutral lock-out cam in the SERVICE position, put the forward and reverse lever in the NEU- TRAL position, and chock the wheels. 2. Remove the plug wire from the spark plug. Using an ignition spark gap test tool (Thexton 404® or equivalent), check for correct spark (Figure 12-29, Page 12-21).
  • Page 159 If the engine runs properly, keep the new RPM Limiter in the circuit. Test Procedure 14 - Ignition Coil: DANGER • DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTI- LATION. ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS, DEADLY POI- SON.
  • Page 160 Test Procedure 15 - Disconnected Kill Wire: 1. Place the neutral lock-out cam in the SERVICE position, put the forward and reverse lever in the NEU- TRAL position, and chock the wheels. 2. Remove the spark plug wire from the spark plug. Using an ignition spark-gap test tool (Thexton 404® or equivalent), check for correct spark to plug.
  • Page 161 Without the lever depressed, the reading should be no continuity. Depress the lever, and the reading should be continuity. If either reading is incorrect, replace the limit switch (Figure 12-35). Test Procedure 17 - Key Switch (Engine Kill Circuit): 1. Place the neutral lock-out cam in the SERVICE position, put the forward and reverse lever in the NEU- TRAL position, and chock the wheels.
  • Page 162 Test Procedure 21 - Oil Warning Light: 1. Place the neutral lock-out cam in the SERVICE position, put the forward and reverse lever in the NEU- TRAL position, and chock the wheels. 2. Remove the center dash assembly (See Removing the Oil Light, Page 12-46). 3.
  • Page 163: Electrical System Components

    ELECTRICAL SYSTEM COMPONENTS WARNING • WHEN MAKING ELECTRICAL TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. - REMOVE THE KEY. - PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL. - DISCONNECT THE BATTERY AS SHOWN (FIGURE 12-1, PAGE 12-2). •...
  • Page 164 Disassembly of the Starter/Generator to Service Brushes, Continued: NOTE • IF THE BRUSHES ARE NOT REMOVED, CONTACT BETWEEN THE BRUSHES AND COMMUTA- TOR AS THE COMMUTATOR END COVER IS BEING REMOVED OR INSTALLED COULD POSSI- BLY DAMAGE THE BRUSHES. LIFT THE BRUSH SPRINGS OUT OF THE NOTCHES IN THE BRUSHES AND PULL THE BRUSHES BACK FROM THE CENTER OF THE COMMUTATOR END COVER.
  • Page 165 Cleaning, Inspection, and Replacement of Brush Springs 1. Visually inspect springs. Replace all four springs if any spring is discolored from heat (straw or bluish in color). 2. Install the four brushes (27) into their holders and insert the four brush springs (28) (Figure 12-41). Using a spring scale, test brush spring tension.
  • Page 166 Assembly of the Starter/Generator, Continued: 3. Install the commutator end cover (23) onto the armature shaft. Align the locating pin with the pin hole in the cover. Install the two M6 x 180mm screws (20) (for vehicles prior to serial number 9533-452031 the generators have lockwashers and flat washers with the screws) and tighten to 95-104 in.lbs.
  • Page 167 Starter/Generator with flats on the shaft Starter/Generator with a keyed shaft FIGURE 12-44 2. There are two types of generators. Some use a shaft key; others use a shaft with flats to hold the pul- ley. The shaft with flats also uses a flat washer against the pulley. To separate armature (31 or 33) from output end cover (36), remove nut (41), lockwasher (40), pulley (38 or 39), shaft key (34), spacer (37), bearing retainer screws (43) and washers (for vehicles prior to serial number 9533-452031, the gener- ators use washers and lockwashers with the bearing retaining screws) (Figure 12-44).
  • Page 168 Make sure the wedge attachment tool is supporting the inner race of the bearing. If a press is not avail- able, secure a bearing puller (Club Car Part No. 1012811) to the wedge attachment tool and pull the bearing off of the end of the armature shaft. Support the armature so that it will not drop when the bear- ing is removed (Figure 12-46) 2.
  • Page 169 NOTE • DO NOT REMOVE THE INSULATORS OR THE FIELD COILS UNLESS ELECTRICAL TEST INDI- CATES THAT IT IS NECESSARY (FIGURE 12-47). SEE TEST PROCEDURE NO. 7, PAGE 12-19. Visual Inspection of Armature WARNING • WHEN MAKING ELECTRICAL TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION.
  • Page 170 Cleaning, Inspection, and Replacement of the Commutator 1. Clean the carbon dust, dirt and oil from the commutator. Visually inspect the commutator for worn, burned or glazed areas. Check for loose or raised commutator bars. Slight roughness of the commuta- tor can be polished away with 400 or finer sandpaper (See Caution below).
  • Page 171 Reworking the Starter/Generator Any rework must be performed by a qualified technician. Starter/Generator service specifications are listed in the table below. ITEM SERVICE LIMIT Commutator diameter (minimum) 1.535 inches (39 millimeters) Concentric with armature shaft within .002 inch (0.051 millimeter) Limit depth of cut when machining commutator .005 inch (0.127 millimeter) (For Vehicles prior to Serial No.
  • Page 172 Starter/Generator Assembly, Continued: 5. Slide the housing with field coils over the armature. Use the locating pin to align housing to the cover. NOTE • THE TERMINAL INSULATORS SHOULD BE ON THE COMMUTATOR END OF THE HOUSING. 6. To prevent contact between the brushes and commutator as the commutator cover is installed, and possible damage to the brushes, lift the brush springs out of the notches in the brushes and pull the brushes back from the center of the commutator end cover.
  • Page 173 (3) around the pulley (10) on the end of the starter/generator (1). Place the ten- sion tool (13) (Club Car Part No. 1016867) between the starter/generator and the starter/generator mounting bracket (2) so that the tension tool will lift up the starter/generator.
  • Page 174: Voltage Regulator

    Belt Adjustment, Continued: NOTE • IF A BURROUGHS GAUGE IS USED, TENSION SHOULD BE ADJUSTED TO 120 LBS. FOR A NEW BELT OR 80-100 LBS FOR A PREVIOUSLY USED BELT. Reinstall the access panel (Figure 12-37, Page 12-26). VOLTAGE REGULATOR Removing the Voltage Regulator WARNING •...
  • Page 175: Key Switch

    NOTE • IF A THREE-WIRE REGULATOR IS BEING REPLACED WITH A TWO-WIRE REGULATOR (1), ON A VEHICLE MANUFACTURED PRIOR TO WEEK 9544, IT IS NECESSARY TO REMOVE AND DIS- CARD THE EXISTING GROUND WIRE MOUNTING BOLT (6) AND LOCK NUT (4) LOCATED IN THE ELECTRICAL COMPONENT BOX (FIGURE 12-51).
  • Page 176: Solenoid

    • On vehicles prior to Serial No. 9522-436452, remove the key switch from the dash by holding the key switch and turning the nut on the outside of the dash with the key switch tool (Club Car Part No. 1012801) •...
  • Page 177: Fuse

    FUSE Removing the Fuse 1. Remove seat from body. 2. Disconnect battery wires as shown (Figure 12-1, Page 12-2). 3. Remove electrical component box cover. 4. Remove the fuse from the fuse block. Installing the Fuse 1. Install the fuse. Use a 10 amp fuse only. WARNING •...
  • Page 178 KILL LIMIT SWITCH Removing the Kill Limit Switch (Figure 12-53) WARNING • WHEN MAKING ELECTRICAL TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. - REMOVE THE KEY. - PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL. - DISCONNECT THE BATTERY AS SHOWN (FIGURE 12-1, PAGE 12-2).
  • Page 179 4. Depress and release the accelerator pedal to make sure that both switches are being actuated when the pedal is released. 5. Connect battery cables, positive cable first. 6. Install the seat on the rear body. NEUTRAL LOCK-OUT LIMIT SWITCH Removing the Neutral Lock-out Limit Switch (Figure 12-54) 1.
  • Page 180: Neutral Lock-Out Cam

    NEUTRAL LOCK-OUT CAM If the cam lobes have worn to the point where they will no longer actuate the neutral lock-out limit switch, the cam must be replaced. WARNING • WHEN MAKING ELECTRICAL TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. - REMOVE THE KEY.
  • Page 181: Reverse Buzzer Limit Switch

    6. Slide 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. 7. Disconnect the wires from the reverse warning buzzer. Do not allow wires to touch (Figure 12-56). 8.
  • Page 182: Oil Warning Light

    BATTERY General Information 1. The battery on the DS gasoline car is a 12-volt, low maintenance battery. When changing a 12-volt bat- tery in any Club Car gasoline-powered vehicle, the same size battery with adequate amperage ratings should be used as a replacement.
  • Page 183 2. Club Car recommends a group 70, side-post battery (Club Car Part No. 1012328), with a 460 cold- cranking amp rating and a reserve capacity of 85 minutes. The group 70 classification indicates battery size (8 1/4 inches W x 6 1/2 inches D x 7 1/4 inches H). It is important to use the proper size to ensure that the battery hold-down will fit correctly and secure the battery in the vehicle’s main frame.
  • Page 184 Self-Discharge, Continued: 2. Hot weather also has an effect on a battery’s self-discharge rate. The higher the temperature, the quicker a battery will discharge. In hotter climates, therefore, the battery should be checked more often. When storing the battery, keep in a cool place (See Battery Storage, Page 12-53). Water Level Add water only after charging unless the water is below the level of the plates.
  • Page 185 Inspect the hold-down bracket for rust, corrosion or damage. If both ends of the bracket cannot be fastened securely to the main frame, replace it with a new stainless steel battery hold-down, (Club Car Part No. 1013882), stainless steel flat washers (Club Car Part No. 1011964), and stainless steel nylon insert locknuts (Club Car Part No.
  • Page 186 Performing the Hydrometer Test, Continued: 7. Record the reading. 8. Return the electrolyte to the cell from which it was taken. Replace vent cap. 9. Repeat steps 2-8 on all cells. Hydrometer Calibration BATTERY HYDROMETER PLATES TEST HOLD THE HYDROMETER WATER LEVEL AT EYE LEVEL.
  • Page 187 VOLTAGE TEST See Testing the Battery, Page 12-7, or Test Procedure 2, Page 12-15. Load Test 1. Using a 160 ampere load tester, connect the load tester to the battery posts. 2. Read the battery voltage after the load tester has been on the battery for 5 seconds. Compare the bat- tery’s voltage reading with the table below.
  • Page 188 Removing the Battery, Continued: 1. Remove the seat from the rear body. 2. Disconnect the air hose that is clamped to the carburetor. Remove the retention strap and lift the intake expansion chamber out of the vehicle. Make sure the O-ring is kept with the intake expansion chamber. 3.
  • Page 189 WARNING WARNING, continued: • IF THE CHARGER MUST BE STOPPED, DISCONNECT THE AC SUPPLY CORD FROM THE WALL OUTLET BEFORE DISCONNECTING THE D.C. LEADS FROM THE BATTERY. ALLOW THE BATTERY TO COOL TO ROOM TEMPERATURE AND RESUME CHARGING BATTERY AT A LOWER AMP RATE.
  • Page 190 ARE SECURELY CONNECTED AT ALL TIMES. There are three ground straps on the DS Gasoline which ground the electrical system to the frame. 1. One of the straps is attached to the A1 terminal of the starter/generator and to the frame seat support (Figure 12-60).
  • Page 191: Fe 290 Engine

    - DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG. GENERAL INFORMATION The CLUB CAR DS Gasoline golf car is powered by a 4-cycle, overhead valve, single cylinder, air cooled engine. The 4-cycle engine has an oil reservoir (crankcase) similar to automobiles, trucks, aircraft, heavy equipment, machinery and other applications designed for reliable heavy duty service.
  • Page 192: Special Tools

    General Information, Continued: SPECIAL TOOLS DESCRIPTION PART NUMBER Gear Yoke 1016418 Compression Gauge and Adapter 1016410-02 Valve Spring Compressor 1016411-01 Valve Guide Reamer 1016412-01 Valve Guide Reamer Arbor 1016412-02 Piston Ring Compressor Grip 1016414-01 Piston Ring Compressor Belt 1016414-02 Piston Ring Pliers 1016415 Bearing Driver Set 1016416...
  • Page 193 Dirt Clean the engine thoroughly before servicing it. WARNING • BEFORE REMOVAL AND DISASSEMBLY, CLEAN THE ENGINE. ANY DIRT ENTERING THE ENGINE, CARBURETOR, OR OTHER PARTS WILL WORK AS AN ABRASIVE AND SHORTEN THE LIFE OF THE ENGINE. FOR THE SAME REASON, BEFORE INSTALLING A NEW PART, CLEAN OFF ANY DUST OR METAL FILINGS.
  • Page 194: Electrical System

    Liquid Gasket and Non-permanent Locking Agent Follow manufacturer’s directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a non-permanent locking agent commonly available in North America is Loctite ®, Lock’n Seal (Blue). Ball Bearing Installation When installing a ball bearing, the bearing race which has the press fit should be pushed by a suitable driver.
  • Page 195: Lubrication System

    LUBRICATION SYSTEM (FIGURES 13-1, 13-2, AND 13-3) CUTAWAY VIEW OF CRANKCASE FIGURE 13-1 The DS OHV is equipped with a pressurized lubrication system which consists of these components (Figure 13-2): • Inlet filter (2) • Trochoid pump (3) • Cartridge filter (5) •...
  • Page 196: Spark Plug

    Spark plugs are selected to suit specific engine design and vehicle operating conditions. The spark plug is designed to give maximum life and efficient combustion of fuel. Original equipment plug number is Club Car Part Number 1018811-01. An acceptable replacement is a Champion N11YC. The spark gap is .027-.031 inches (0.69-0.79 millimeter).
  • Page 197: Cylinder Head

    Testing the Spark Plug (See Section 12, Test Procedure 11 - Ignition Spark, Page 12-21.) Setting the Spark Gap 1. Before setting the spark gap on a used plug, pass a contact point file between the electrodes to pro- duce flat, parallel surfaces to facilitate accurate gauging. 2.
  • Page 198 CYLINDER SHROUD REMOVAL WARNING • WHEN MAKING TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. - REMOVE KEY. - DO NOT ATTEMPT TO SERVICE HOT ENGINE OR EXHAUST. - DISCONNECT BATTERY AS SHOWN (FIGURE 12-1, PAGE 12-2). - REMOVE SPARK PLUG WIRE.
  • Page 199 FIGURE 13-6 8. Remove carburetor (4) along with throttle spring (8) and throttle spring bracket (23) (Figure 13-6). 9. Remove muffler (See Exhaust System - Section 15). 10. If the engine is to be totally disassembled, drain oil and remove the oil filter. If only the cylinder head is to disassembled, proceed without draining the oil or removing the oil filter.
  • Page 200 Cylinder Shroud Removal, Continued: FIGURE 13-9 FIGURE 13-10 11. Disconnect oil filler tube (20) from cylinder shroud by first removing nut (18) and pulling oil filler tube out of the crankcase (Figure 13-8, Page 13-9). NOTE • IF THE CAR IS NOT LEVEL, THEN OIL WILL SPILL WHEN OIL FILLER TUBE IS REMOVED. 12.
  • Page 201 2. Remove head gasket (3). Note the position of the two dowels (4) as shown (Figure 13-12). 3. Compress the valve spring with the valve spring compressor (5) (CLUB CAR Part Number 1016411- 01) and remove the collet halves (6) (Figure 13-13).
  • Page 202 BREATHER VALVE (REED VALVE) General Information The function of the breather is to create a vacuum in the crankcase, which prevents oil from being forced out of the engine through the piston rings, oil seals or gaskets. The breather has a reed valve, which limits the direction of air flow caused by the piston moving up and down.
  • Page 203 1. With the combustion chamber side of the head facing up, drive the guide out of the head with the valve guide arbor (1) (CLUB CAR Part Number 1016412-02) (Figure 13-19). 2. Install the snap ring (2) on the new valve guide (Figure 13-20).
  • Page 204 (3) until the snap ring (2) just seats on the head (Figure 13-20, Page 13-13). 5. Ream the guide with a stanisol or kerosene lubricant and a valve guide reamer (CLUB CAR Part Num- ber 1016412-01). Valve guide inside diameter should be 0.2756-0.2762 inches (7.000-7.015 millime- ters) (Figure13-21).
  • Page 205 OR ALLOW IT TO HIT A METAL OBJECT. 2.5. Use a 32° seat cutter (1) (CLUB CAR Part Number 1016555) to narrow the seat width to the stan- dard width (Figure 13-24) (See Caution Below and Note on Page 13-16).
  • Page 206 • KEEP THE SEAT WIDTH AS CLOSE AS POSSIBLE TO 0.031 INCH (0.8 MILLIMETERS). 2.7. Make a light pass with the 45° cutter (1) (32mm Exhaust Valve Seat Cutter, CLUB CAR Part Num- ber 1016553, and 35mm Intake Valve Seat Cutter, CLUB CAR Part Number 1016554) to remove any possible burrs at the edge of the seat.
  • Page 207 VALVES WARNING • WHEN MAKING TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. - REMOVE KEY. - DO NOT ATTEMPT TO SERVICE HOT ENGINE OR EXHAUST. - DISCONNECT BATTERY AS SHOWN (FIGURE 12-1, PAGE 12-2). - REMOVE SPARK PLUG WIRE. •...
  • Page 208 Stem Diameter MEASURE EACH POSITION IN 2 PLACES 90° APART FIGURE 13-31 FIGURE 13-32 1. Using a micrometer, measure the diameter of the stem at several points along its length (Figure 13-30, Page 13-17). 2. If the outside diameter is less than the service limit of 0.2728 inch (6.930 millimeters) intake, 0.2722 inches (6.915 millimeters) exhaust, replace the valve.
  • Page 209 2. Using a micrometer, measure the outside diameter of the rocker shaft at several points along its length (Figure 13-33). FIGURE 13-35 3. If the outside diameter is less than the service limit of 0.4704 inch (11.949 millimeters), replace the shaft.
  • Page 210 Cylinder Head Installation, Continued: 3. Slide the washer (4) against the exhaust rocker, and fit the E-ring (1) into the groove in the rocker shaft (2) (Figure 13-35, Page 13-19). CYLINDER HEAD BOLT TORQUE SEQUENCE FIGURE 13-37 FIGURE 13-38 4. Install cylinder head assembly to engine. 5.
  • Page 211 4. If necessary, loosen the locknut (3) and turn the adjuster (6) up or down to adjust the clearance to 0.005 inches (0.127 millimeters) for both intake and exhaust (Figure 13-38). 5. While keeping the adjuster from turning with the screw holder (5) (CLUB CAR Part Number 1016413), tighten the locknut (3) to 90 in-lbs. (10 N-m) (Figure 13-38).
  • Page 212 INSTALLATION OF REMAINING ENGINE COMPONENTS WARNING • WHEN MAKING TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. - REMOVE KEY. - DO NOT ATTEMPT TO SERVICE HOT ENGINE OR EXHAUST. - DISCONNECT BATTERY AS SHOWN (FIGURE 12-1, PAGE 12-2). - REMOVE SPARK PLUG WIRE.
  • Page 213 FIGURE 13-41 FIGURE 13-42 CRANKCASE ENGINE REMOVAL WARNING • WHEN MAKING TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. - REMOVE KEY. - DO NOT ATTEMPT TO SERVICE HOT ENGINE OR EXHAUST. - DISCONNECT BATTERY AS SHOWN (FIGURE 12-1, PAGE 12-2). - REMOVE SPARK PLUG WIRE.
  • Page 214 Engine Removal, Continued: FIGURE 13-43 FIGURE 13-44 11. Remove muffler (See Exhaust System - Section 15). 12. Disconnect oil sending unit wire from engine crankcase. 13. Remove engine mounting hardware. 14. Lift engine from car. 15. Remove crankcase oil drain plugs and filler tube. Tip the engine slightly to allow all of the oil to drain from the crankcase.
  • Page 215 Removal (Figure 13-44) 1. Turn the engine upside down to keep the tappets (1) from catching the cam lobes. 2. Take the camshaft out of the engine block. Pull both tappets out. Inspection 1. Inspect the camshaft for wear or broken gear teeth. 2.
  • Page 216 Piston Inspection and Repair, Continued: FIGURE 13-47 FIGURE 13-48 3. Be sure the oil return passages in the ring grooves are open. 4. Visually inspect the piston rings and grooves for uneven wear or damage. Replace them if uneven wear or damage is excessive.
  • Page 217 5. If either ring thickness is less than 0.0566 inches (1.438 millimeters), replace the entire set of rings. NOTE • IT IS DIFFICULT TO MEASURE EXACTLY THE OIL RING THICKNESS. REPLACE THE OIL RING WHENEVER THE COMPRESSION RINGS (TOP AND SECOND) ARE REPLACED. PISTON PIN Inspection WARNING...
  • Page 218 Connecting Rod Inspection 1. Clean and inspect the bearing surfaces of the connecting rod and cap. Replace parts if scored. 2. Using an inside micrometer or a telescoping gauge, measure the inside diameter of the connecting rod small bore at several points along its length (Figure 13-53). 3.
  • Page 219 NOTE • IMPORTANT: THE CYLINDER WALL FINISH SHOULD HAVE A 40° TO 60° CROSS-HATCH PAT- TERN. DO NOT USE SOLVENTS OR GASOLINE (FIGURE 13-56). 3. After honing, clean the cylinder wall thoroughly using soap, warm water and clean rags. MEASURE EACH LEVEL IN BORE AT 2 PLACES 90°...
  • Page 220 To Resize Bore to Next Oversize, Continued: LOOSEN REMOVE REMOVE FIGURE 13-57 FIGURE 13-58 4. Dry the cylinder and coat with engine oil. CAUTION • THE CYLINDER MUST BE THOROUGHLY CLEANED AFTER HONING TO ELIMINATE ALL GRIT. IGNITION COIL AND FLYWHEEL Removal 1.
  • Page 221: Oil Pump

    4. Pull off the flywheel with a puller (CLUB CAR Part Number 1016627). 5. Take the flywheel key out of its groove. Ignition Coil Inspection and Repair See Testing the Engine Ignition Circuit - Section 12, Page 12-9. Installation 1. Installation is the reverse of removal.
  • Page 222 Oil Pump Inspection MEASURE TWO PLACES 90° APART FIGURE 13-62 FIGURE 13-63 1. Check the clearance between the inner and outer rotors (5) with a feeler gauge (6). Measure the clear- ance between the high point of the inner rotor and the high point of the outer rotor (Figure 13-62). 2.
  • Page 223 OIL PRESSURE RELIEF VALVE Removal WARNING • WHEN MAKING TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. - REMOVE KEY. - DO NOT ATTEMPT TO SERVICE HOT ENGINE OR EXHAUST. - DISCONNECT BATTERY AS SHOWN (FIGURE 12-1, PAGE 12-2). - REMOVE SPARK PLUG WIRE.
  • Page 224 1. Slide the spacer (2) and the link rod (3) off the flywheel end of the crankshaft. Remove the balancer from the remaining link rod (Figure 13-70). 2. Place the gear yoke (CLUB CAR Part Number 1016418) under the spur gear with the small end of the connecting rod opposite the crankpin (Figure 13-71).
  • Page 225 • ALWAYS USE A PRESS WHEN REMOVING THE SPUR GEAR AND HELICAL GEAR FROM, OR INSTALLING THEM ON THE CRANKSHAFT. 5. Remove the woodruff key. Slide the remaining link rod off of the crankshaft. GEAR YOKE HELICAL GEAR CLUB CAR PART NO.1016418 SPUR GEAR PRESS RAM GEAR YOKE SIDE BLOCKS...
  • Page 226 Link Rod Inspection, Continued: 0.039" (0.991 mm) FIGURE 13-75 FIGURE 13-76 1.3. If the inside diameter of the large end is greater than 1.8554 inches (47.127 millimeters), replace the bushing (Figure 13-74, Page 13-35). Link Rod Bushing Replacement 1. Support the link rod around the entire big end, and using a 1.97 inch (50 millimeters) bearing driver (1), drive the bushing (2) out of the rod (3), as shown (Figure 13-75).
  • Page 227 BALANCER GUIDE PIN (FIGURE 13-78) 1. Clean the pin surface and inspect it for wear or damage. Replace balancer guide pin if necessary. 2. With an outside micrometer, measure the outside diameter of the balancer guide pin surface. 3. If the outside diameter is smaller than 1.0199 inch (25.907 millimeters), replace the guide pin. 4.
  • Page 228 Crankshaft Inspection, Continued: 8.2. Turn the crankshaft (1) slowly and measure total indicated run-out at the location shown (2) (Fig- ure 13-82). 8.3. If total run-out exceeds 0.002 inch (0.051 millimeter), replace the crankshaft. MEASURE IN 2 PLACES 90° APART FIGURE 13-81 FIGURE 13-82 UNDERSIZED CONNECTING ROD...
  • Page 229 2. Place the crankcase cover (1) on a bench with its outside up (gasket surface against the bench) (Fig- ure 13-85). 3. Using a bearing driver (2) (Part of CLUB CAR Bearing Driver Kit, Part Number 1016416), drive out the ball bearing (3) as shown.
  • Page 230 Oil Seals, Continued: FIGURE 13-86 FIGURE 13-87 Oil Seal Removal Use an oil seal remover to press or drive the seal out of the casing. Oil Seal Installation NOTE • NEVER REUSE AN OIL SEAL. ALWAYS REPLACE THE OIL SEAL WITH A NEW ONE. 1.
  • Page 231 CRANKSHAFT INSTALLATION (FIGURES 13-89 AND 13-90) WARNING • WHEN MAKING TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. - REMOVE KEY. - DO NOT ATTEMPT TO SERVICE HOT ENGINE OR EXHAUST. - DISCONNECT BATTERY AS SHOWN (FIGURE 12-1, PAGE 12-2). - REMOVE SPARK PLUG WIRE.
  • Page 232 Crankshaft Installation, Continued: CHAMFERED INSIDE DIAMETER CHAMFERED INSIDE DIAMETER FIGURE 13-91 3. With the crankweb supported as shown, slide the link rod onto the PTO side of the crankshaft, and install the key. Press the spur gear and helical gear onto the crankshaft (Figures 13-89 and 13-90, Page 13-41).
  • Page 233 5. Put the piston/connecting rod into the cylinder bore with the lettering MADE IN JAPAN on the con- necting rod oriented toward the clutch side of the engine (Figure 13-92). Position piston ring gaps so that they are oriented toward the corresponding letters in: (A) Top Ring Gap, (B) Second Ring Gap, (C) Upper Side Rail Gap installed in the lowest ring groove, (D) Lower Side Rail Gap installed in the lowest ring groove.
  • Page 234 Crankshaft Axial Play Adjustment, Continued: 17.83 17.71 15.75 15.80 15.85 15.90 15.95 16.00 16.05 16.10 16.15 16.20 16.25 Measurement (A) Measurements in Millimeters FIGURE 13-96 FIGURE 13-97 FIGURE 13-98 CAMSHAFT INSTALLATION CAUTION • WHEN INSTALLING THE CAMSHAFT, MAKE SURE THAT THE TANG (1) ON THE OIL PUMP ROTOR SEATS IN THE SLOT (2) IN END OF THE CAMSHAFT (FIGURE 13-98).
  • Page 235 3. Align the timing marks (3) (Figure 13-97). NOTE • IF THE OUTSIDE EDGES OF THE CAMSHAFT AND CRANKSHAFT GEARS ARE NOT FLUSH, AND THE CRANKCASE COVER WILL NOT EASILY MAKE FULL CONTACT WITH THE CRANK- CASE, MAKE SURE THE TANG ON THE OIL PUMP ROTOR IS SEATED IN THE CAMSHAFT SLOT.
  • Page 236: Engine Assembly

    ENGINE ASSEMBLY WARNING • WHEN MAKING TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. - REMOVE KEY. - DO NOT ATTEMPT TO SERVICE HOT ENGINE OR EXHAUST. - DISCONNECT BATTERY AS SHOWN (FIGURE 12-1, PAGE 12-2). - REMOVE SPARK PLUG WIRE.
  • Page 237: Service Specifications

    13. Connect impulse line of fuel pump to engine. 14. Install air intake hose (See Fuel System - Section 14). 15. Install throttle cable and governor linkages (See Fuel System - Section 14, Engine Control Linkage). 16. Connect wire to the oil sending unit on the crankcase cover. 17.
  • Page 238 ITEM SPEC. SERVICE LIMIT Camshaft Axial Play 0.0137 in. (0.35 mm) Camshaft PTO-Side Journal O.D. (MIN.) 0.9026 in. (22.927 mm) Camshaft Flywheel-Side Journal O.D. (MIN.) 0.9026 in. (22.927 mm) Camshaft Cam Lobes (IN. and EX.) O.D. (MIN.) 1.287 in. (32.70 mm) Connecting Rod Big-End Bearing I.D.
  • Page 239: Specifications For Resizing Cylinder Bore

    ITEM SPEC. SERVICE LIMIT Valve Guide Hole (Exhaust) I.D. (MAX.) 0.2781 in. (7.065 mm) Valve Spring (Free Length) (MIN.) 1.2894 in. (32.75 mm) Oil Pump Shaft O.D. (MIN.) 0.4971 in. (12.627 mm) Outer Rotor O.D. (MIN.) 1.5932 in. (40.467 mm) Outer Rotor Width (MIN.) 0.3905 in.
  • Page 240: Adjustments And Settings

    ADJUSTMENT AND SETTINGS ITEM LIMITS Spark Plug Gap (Standard) 0.027 to 0.031 in. (0.7 to 0.8 mm) Ignition Coil Air Gap (Standard) 0.012 in. (0.304 mm) Oil Pressure (MIN.) at governed speed 45.5 psi. (314 kPa) Oil Filter: bypass-valve opening pressure 11.4 to 17.0 psi.
  • Page 241: Fuel System

    SECTION 14 - FUEL SYSTEM 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. •...
  • Page 242 Main System, Continued: VENTURI INTAKE FUEL TANK AIR CLEANER ENGINE FLOAT MAIN AIR CARBURETOR INTAKE STROKE CHAMBER PASSAGE BORE OF PISTON CARBURETOR FUEL MAIN MAIN JET BLEED PIPE NOZZLE AIR / FUEL MIXTURE FIGURE 14-1 FIGURE 14-2 Trouble in the main system is usually indicated by poor running, or lack of power under heavy load condi- tions.
  • Page 243 BYPASS HOLES TOP VIEW MAIN AIR JET MAIN NOZZLE THROTTLE VALVE MIXTURE INTAKE CYLINDER CARBURETOR BORE MAIN AIR PASSAGE TO ENGINE PILOT AIR JET PILOT OUTLET PILOT AIR SCREW PILOT JET FUEL FUEL FUEL AIR / FUEL MIXTURE SIDE VIEW MAIN AIR PASSAGE CARBURETOR BORE TO ENGINE...
  • Page 244: Carburetor

    Float System, Continued: SIDE VIEW END VIEW FUEL FUEL AIR / FUEL MIXTURE FUEL INLET FUEL CARBURETOR LEVEL NEEDLE FLOAT VALVE FUEL FIGURE 14-4 FIGURE 14-5 CARBURETOR Before suspecting the carburetor as the cause of poor engine performance, make sure that the fuel and igni- tion systems are in proper operating condition.
  • Page 245 PROCEDURE FOR CHANGING MAIN JET DANGER • GASOLINE! FLAMMABLE! EXPLOSIVE! DO NOT SMOKE. KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE. • THE ENGINE PRODUCES CARBON MONOXIDE, WHICH IS AN ODORLESS AND DEADLY POI- SON. DO NOT OPERATE THE ENGINE IN AN ENCLOSED AREA WITHOUT PROPER VENTILA- TION.
  • Page 246 Procedure for Changing Main Jet, Continued: NOTE • NOTE THE ORIENTATION OF THE GASKET (16), BETWEEN THE CARBURETOR INTAKE MANI- FOLD (17) AND THE CARBURETOR BODY (12), SO THAT IT CAN BE REPLACED WITH THE SAME ORIENTATION. • WHEN REMOVING THE CARBURETOR BODY, THE THROTTLE RETURN SPRING (11) MUST BE DISCONNECTED.
  • Page 247 2. Position the carburetor with the drain screw (11) over a catch basin (Figure 14-7). 3. Turn the carburetor bowl drain screw counterclockwise two or three turns and drain all of the fuel from the bowl into the catch basin (Figure 14-7). Tighten the drain screw to 6-13 in.lbs. (0.7/1.5 N-m). 4.
  • Page 248: Engine Control Linkage

    Procedure for Changing Main Jet, Continued: 7. Select the proper size main jet. Check the size designation marking on the jet to insure that it is the cor- rect part. 8. Install the new main jet and tighten it to 11-13 in.lbs. (1.2/1.5 N-m). NOTE •...
  • Page 249 2. Be sure the key switch is OFF before disconnecting the accelerator rod. Remove the accelerator rod by disconnecting the ball joint (1) from the ball stud (2) on the accelerator pedal (Figure 14-8) and from the bell crank at the electrical box (See Figure 14-10, Page 14-10). GASOLINE VEHICLES GASOLINE VEHICLES SERIAL NUMBER...
  • Page 250 Accelerator Rod Installation and Adjustment 1. Before installing the accelerator rod, adjust accelerator pedal position (See Section 6). 2. Install the ball joint on the ball stud at the accelerator pedal (Figure 14-8, Page 14-9). 3. If the seat is in place on the rear body, remove it. 4.
  • Page 251 9. While holding the accelerator ball joint with pliers, tighten the jam nuts against the ball joints, accelera- tor ball joint first, at each end of the accelerator rod. 10. Again check rod adjustment for proper switch activation. 11. Install the electrical box cover. 12.
  • Page 252 Governor Cable Installation and Adjustment, Continued: 6. While holding the arm and shaft in the fully counterclockwise position, tighten the governor arm lever nut to 36 in.lbs. (4.0 N-m). 7. Check governed speed adjustment as instructed on Page 14-14. FIGURE 14-11 ACCELERATOR CABLE WARNING •...
  • Page 253 WARNING • TURN KEY SWITCH OFF, PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI- TION, AND REMOVE KEY BEFORE SERVICING THE VEHICLE. • MOVING PARTS! - DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING. • ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON- NECTIONS.
  • Page 254: Choke And Intake System

    3. Place the forward and reverse lever in the NEUTRAL position and place the neutral lockout cam in the SERVICE position. 4. Connect a tachometer (Club Car Part No. 1016112) to the spark plug lead. 5. With the tachometer connected, check high speed RPM. With the accelerator pedal pressed to the floor, the tachometer should read 2675 ±50 RPM.
  • Page 255 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. •...
  • Page 256 Air Filter Element, Continued: TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES FIGURE 14-12 WARNING • ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE. WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES. •...
  • Page 257: Fuel Filters

    2.1. Remove the clamps (16) and fuel lines (18 and 19) from the filter (Figure 14-13, Page 14-18). 2.2. To prevent draining of gasoline, plug the fuel lines (18 and 19) (Figure 14-13, Page 14-18). 3. Remove the secondary filter (24) (Figure 14-13, Page 14-18): 3.1.
  • Page 258 Fuel Filters, Continued: GAS TANK VENT TUBE #2 FUEL LINE #1 FUEL LINE IMPULSE LINE #3 FUEL LINE CARBURETOR AIR VENT TUBE #4 FUEL LINE FUEL LINE # ROUTING COLOR LENGTH FUEL TANK TO PRIMARY FUEL FILTER CLEAR 2" (5.1 cm) PRIMARY FUEL FILTER TO FUEL PUMP CLEAR 6"...
  • Page 259: Fuel Pump

    5. Place the neutral lockout cam in the OPERATE position. FUEL PUMP GENERAL INFORMATION The DS gasoline vehicle is equipped with an impulse fuel pump. If the fuel pump is not operating properly, perform the following tests: • Make sure that all hose clamps are tight.
  • Page 260 FUEL PUMP DISASSEMBLY NOTE • A FUEL PUMP REBUILD KIT IS AVAILABLE FROM CLUB CAR (CLUB CAR PART NO. 1014524). THIS KIT INCLUDES ALL GASKETS, DIAPHRAGMS, AND VALVES. 1. Remove four screws (24) and lock washers (25) from front of the fuel pump (Figure 14-14).
  • Page 261 FUEL PUMP ASSEMBLY 1. Install the fuel gasket (35) and diaphragm (34) on the back cover (36) (Figure 14-14). 2. Install the valve assembly in the pumping chamber (Figure 14-14) . CAUTION • IF THE VALVE ASSEMBLY IS NOT INSTALLED EXACTLY AS SHOWN, THE IMPULSE FUEL PUMP WILL NOT OPERATE PROPERLY.
  • Page 262: Fuel Tank

    FUEL TANK GENERAL INFORMATION The DS gasoline is equipped with a high impact plastic, seven gallon (26.5 liter) fuel tank. If the vehicle is to be placed in extended off-season storage, prepare the vehicle as follows: 1. Place the forward and reverse lever in the NEUTRAL position and the neutral lockout cam in the SER- VICE position.
  • Page 263 2. In a well-ventilated area, flush the fuel tank with water to remove any remaining gasoline. 3. In a well-ventilated area, set the tank upside down so that the water can drain out of it. To make sure that the tank dries completely, allow the tank to sit for 24 hours.
  • Page 264: Fuel Lines

    FUEL LINES The fuel lines on the DS gasoline vehicle must be properly routed, and all hose clamps must be tight. The fuel lines should be kept clean. WARNING • MAKE SURE THAT THE FUEL LINES ARE THE RIGHT LENGTH AND ARE PROPERLY ROUTED.
  • Page 265: Exhaust System

    SECTION 15 - EXHAUST SYSTEM GENERAL INFORMATION The exhaust system on the DS gasoline vehicle is designed to provide quiet vehicle operation. If the muffler should ever need to be removed for repairs or replacement, follow the instructions below. MUFFLER WARNING •...
  • Page 266 • ANYTIME THE MUFFLER IS REMOVED FROM THE VEHICLE, REPLACE THE MUFFLER CLAMP, ITEM 6, FIGURE 15-1 (CLUB CAR PART NO. 1017689) WITH A NEW ONE. 1. Use the muffler clamp (6) to attach the muffler bracket (Item 2) to the muffler as shown (Figure 15-1).
  • Page 267 VICE position. Start the engine and check for exhaust leaks and proper engine operation. See DAN- GER below. DANGER • GASOLINE! FLAMMABLE! EXPLOSIVE! DO NOT SMOKE. KEEP SPARKS AND FLAMES AWAY FROM THE AREA OF THE VEHICLE. • THE ENGINE PRODUCES CARBON MONOXIDE, WHICH IS AN ODORLESS AND DEADLY POI- SON.
  • Page 268 Page 15-4...
  • Page 269: Torque Converter

    SECTION 16 - TORQUE CONVERTER 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 REPAIR. FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL. •...
  • Page 270 • Driven Clutch Cam Puller - Club Car Part No. 1014508 • Press Weldment - Club Car Part No. 1018091-01 All of the tools listed above are available in a torque converter tool kit, Club Car Part No. 1014510 (Figure 16-1).
  • Page 271: Troubleshooting

    Maintaining proper adjustment of the engine and governor, as well as the torque converter, is essential to the troubleshooting process. If these adjustments are within Club Car specifications and, when climbing a steep hill, the engine begins to bog before the drive belt reaches the top of the driven clutch, there is a torque con- verter problem.
  • Page 272: Drive Clutch

    REMOVING THE DRIVE BELT 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 REPAIR. GRASP BELT MIDWAY BETWEEN DRIVE AND DRIVEN CLUTCHES, THEN ROLL BELT OFF DRIVEN CLUTCH DRIVEN CLUTCH...
  • Page 273 • BE VERY CAREFUL WHEN HANDLING THE CLUTCHES. A CLUTCH THAT HAS BEEN DROPPED WILL NOT BE PROPERLY BALANCED. IF EITHER CLUTCH IS DROPPED, ASSUME THAT IT IS DAMAGED AND REPLACE IT. USE CLUB CAR CLUTCH HOLDER VEHICLE BODY WHILE TIGHTENING OR LOOSENING DRIVE...
  • Page 274 4. Loosen the starter/generator mounting and adjusting hardware and then remove the starter belt. 5. Remove the drive clutch retaining bolt (17), lock washer (18), and flat washer (19) (Figure 16-5). 6. Use a Drive Clutch Puller (Club Car Part No. 1014496) to remove the entire drive clutch assembly (See CAUTION below): 6.1.
  • Page 275 FIGURE 16-5 3. Remove the thrust washer (11) from the moveable face (14) (Figure 16-5). 4. Remove the clutch buttons (Figure 16-8, Page 16-9): 4.1. Remove the screws, flat washers, drive button take-up springs, and drive buttons as shown (Fig- ure 16-8).
  • Page 276 CAUTION • BEFORE REMOVING THEM, NOTE THE ORIENTATIONS OF THE WAVE WASHER AND OF THE PRIMARY AND SECONDARY WEIGHTS TO ANOTHER. DRIVE CLUTCH HUB PULLER TOOL (CLUB CAR PART NO. 1014497) MARK THE CLUTCH COVER AND ITS CORRESPONDING POSITION ON THE...
  • Page 277 REMOVE THESE ITEMS FROM RIBS 1/4-20 SCREW 10-24 SCREW FLAT WASHER FLAT WASHER WEIGHT DRIVE BUTTON DRIVE BUTTON TAKE UP SPRING RIBS WEIGHT SLOTS IN HUB CASTING FIGURE 16-8 FIGURE 16-9 USE A SCRIBE TO REMOVE PRESS RAM SPIRAL BACK-UP RINGS FROM BOTH SIDES OF FIXED FACE ASSEMBLY.
  • Page 278 Inspection of Drive Clutch Parts, Continued: 2. Inspect the bore of the moveable face assembly (14) (Figure 16-5, Page 16-7) for scarring or wear. The moveable face assembly must be replaced if the bore is worn to a diameter of .883 inches (22.4 mm) or larger.
  • Page 279 INSTALL WHITE WASHERS ON EACH SIDE OF PIN PIN SHOULD HAVE EQUAL AMOUNTS ON BOTH SIDES FIGURE 16-14 8. Install a wave washer on each mounting pin. Make sure that the concave side of the washer faces the side of the primary weight with the small guide pin protruding from it (Figure 16-12). 9.
  • Page 280: Driven Clutch

    Drive Clutch Assembly, Continued: 12. Install the 1/4-20 screws and washers (2) and tighten them to 10 ft.lbs. (13 N-m). See NOTE below (Figure 16-5, Page 16-7). NOTE • MAKE SURE THAT THERE IS AT LEAST A (MINIMUM) GAP OF .020 INCHES (0.51 MM) BETWEEN EACH END OF THE MOUNTING PIN AND THE MOUNTING SCREW.
  • Page 281 WARNING • HOT! - DO NOT ATTEMPT TO SERVICE HOT ENGINE OR EXHAUST SYSTEM. FAILURE TO HEED THIS WARNING COULD RESULT IN SEVERE BURNS. • FRAME GROUND - DO NOT ALLOW WRENCH OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRIC WIRING. NEVER ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME, ENGINE, INNER FRAME, OR OTHER METAL COMPONENT.
  • Page 282 PERSONAL INJURY. 2. Insert a puller plug (Club Car Part No. 1014507) into the shaft bore and use a driven clutch cam puller (Club Car Part No. 1014508) to remove the cam (5) from the fixed face hub (9). Retain the key (4) (Fig- ure 16-16, Page 16-13) (See Figure 16-20).
  • Page 283 PLACE PULLER PLUG IN BORE OF CAM (A). THEN CLAMP DRIVEN CLUTCH CAM PULLER ONTO THREE FLAT SURFACES OF THE CAM. DRIVEN CLUTCH CAM PULLER PULLER PLUG FIGURE 16-20 3. Remove the spring (6) (Figure 16-16, Page 16-13). 4. Slide the moveable face (8) off of the fixed face hub (9) (Figure 16-16). INSPECTION OF THE DRIVEN CLUTCH 1.
  • Page 284 (Figure 16-16, Page 16-13). 6. Place the clutch assembly in a press and position the cam press tool (Club Car Part No. 1018091-01) on the cam as shown (Figure 16-21). Hold the fixed face assembly and rotate the moveable face assembly (1) one third of a turn counterclockwise, then press the cam (2) onto the fixed face assembly.
  • Page 285: Clutch Alignment

    DRIVEN CLUTCH INSTALLATION 1. To install the driven clutch, reverse the removal procedure. Before tightening the center bolt to 14 ft.lbs. (16/19 N-m), make sure that the flat washer (13), is installed between the center bolt and the clutch (Figure 16-16, Page 16-13). CLUTCH ALIGNMENT WARNING •...
  • Page 287: Transmission And Governor

    ARE DISCONNECTED, BE SURE TO KEEP THEM AWAY FROM BATTERY POSTS AND OTHER WIRES. SERVICE ONLY IN WELL-VENTILATED AREAS. • DO NOT OPERATE A GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTI- LATION. ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS, DEADLY POI- SON.
  • Page 288: General Information

    GENERAL INFORMATION On the DS Gasoline vehicle, power is transferred from the engine to the transaxle and then to the wheels through a drive clutch, drive belt, driven clutch, and transmission. The transmission is mounted directly to the transaxle. The engine, drive clutch, belt, and driven clutch rotate in one direction only, and the transmission is used to reverse vehicle direction.
  • Page 289: Transmission

    removed also to allow the lubricant to drain faster. Be sure the drain plug is cleaned and reinstalled before fill- ing. Torque plug to 18-25 ft.lbs. (24/34 N-m). Use a funnel when filling the transmission with lubricant through level indicator hole. Fill with 20 oz. 80-90 WT. API Class GL-3 or 80-90 WT. AGMA Class 5 EP gear lubricant (Figure 17-2).
  • Page 290 REMOVAL OF THE TRANSMISSION WARNING • WHEN MAKING TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. - REMOVE KEY. - DO NOT ATTEMPT TO SERVICE HOT ENGINE OR EXHAUST. - DISCONNECT BATTERY AS SHOWN (FIGURE 12-1, PAGE 12-2). - REMOVE SPARK PLUG WIRE.
  • Page 291 WHILE BRINGING IT FORWARD THROUGH THE SEAT OPENING Club Car FIGURE 17-8 6. Disconnect accelerator cable by removing the retaining E-ring (3) and then slipping the cable off the short end of the governor arm. Remove governor cable from transmission by removing the cotter pin (6) and clevis pin (8) from the long end of the governor arm (2) (Figure 17-6).
  • Page 292 Disassembly of the Transmission, Continued: REMOVE FIVE GASKET RETAINING BOLTS RETAIN AND DISCARD GASKET DOWEL PINS FIGURE 17-10 FIGURE 17-11 3. Remove four retaining bolts (52) from the cover of the transmission. Make sure the mounting screw (35) from the reverse side is removed and remove the cover (Figure 17-10). WARNING •...
  • Page 293 Governor Disassembly WARNING • WHEN MAKING TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. - REMOVE KEY. - DISCONNECT BATTERY AS SHOWN (FIGURE 12-1, PAGE 12-2). - REMOVE SPARK PLUG WIRE. • CLEAN TRANSMISSION BEFORE DISASSEMBLY. •...
  • Page 294 Governor Disassembly, Continued: FIGURE 17-14 8. Remove governor arm shaft (18) by rotating back and forth. Oil seal (24), upper retaining ring (16) and middle retaining rings (16) will be removed with shaft (Figure 17-14). CAUTION • DO NOT USE EXCESSIVE FORCE WHEN REMOVING GOVERNOR ARM SHAFT. PULLING SIDE- WAYS MAY DAMAGE OR BEND THE SHAFT.
  • Page 295 Main Cluster Disassembly WARNING • WHEN MAKING TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. - REMOVE KEY. - DO NOT ATTEMPT TO SERVICE HOT ENGINE OR EXHAUST. - DISCONNECT BATTERY AS SHOWN (FIGURE 12-1, PAGE 12-2). - REMOVE SPARK PLUG WIRE.
  • Page 296 Main Cluster Disassembly, Continued: MAIN CLUSTER FIGURE 17-18 4. Discard thrust washers (39) (Figure 17-18). Clutch Hub Disassembly WARNING • WHEN MAKING TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. - REMOVE KEY. - DO NOT ATTEMPT TO SERVICE HOT ENGINE OR EXHAUST. - DISCONNECT BATTERY AS SHOWN (FIGURE 12-1, PAGE 12-2).
  • Page 297 1. Remove the two synchro springs (45) from both sides of the clutch hub assembly (Figure 17-19). 2. Slide the sleeve (48) off the clutch hub (46) (Figure 17-19). 3. Remove the synchro inserts (47) (Figure 17-19). Input Shaft Disassembly 1.
  • Page 298 Transmission Housing Disassembly, Continued: 2. Remove air breather (29) and use a high flash-point solvent to clean the air breather (Figure 17-23, Page 17-11). 3. Inspect the shifter shaft (22). If there is oil around the opening, the O-ring (23) should be replaced. If there is no oil, disregard steps 4, 5, and 6 below (Figure 17-23, Page 17-11).
  • Page 299 3.1. To remove the outer race, apply a few drops of a loosening agent between the outer race and bearing seat. Use a slide hammer to remove the outer race and discard (Figure 17-28). CAUTION • IF TRANSMISSION COVER IS DAMAGED OR OUTER RACE OF BEARING CANNOT BE REMOVED, A NEW COVER AND BEARING MUST BE INSTALLED.
  • Page 300 3. Oil seal press jig (Club Car Part No. 1014105) 4. Internal governor arm alignment tool (Club Car Part No. 1014107) All of these tools are available in a transmission tool kit (Club Car Part No. 1014115) (Figure 17-34). REPLACE SLEEVE IF THICKNESS (T) MEASURE EACH POSITION IS LESS THAN .040 INCH...
  • Page 301 1. Put a light coating of clean transmission oil on the outside edge of the seal to assist installation. Press oil seal (31) into the output shaft bore using transmission oil seal tool (Club Car Part No. 1014160). Oil seal should be flush with the outside cover surface (Figure 17-3, Page 17-3).
  • Page 302 Cover Assembly, Continued: 3. If input shaft needle bearing (60) was removed, press in a new bearing (Figure 17-25, Page 17-12). CAUTION • PRESS ONLY AGAINST OUTER RACE OF BEARING. NOTE • APPLY CLEAN TRANSMISSION OIL TO NEEDLE BEARING AND APPLY GREASE AROUND THE O-RING.
  • Page 303 NOTE • APPLY CLEAN TRANSMISSION LUBRICANT TO THE INSIDE DIAMETERS OF GEARS (49 AND 41) AND SYNCHRONIZER RINGS (42). 1. Slide the thrust washer (43) onto the end of the output shaft with the inner spline. Place the gear assembly (49) (wider gear), new thrust washer (39), Belleville spring washer (73) and the ball bearing (38) onto the end of the output shaft.
  • Page 304 (Figure 17-36, Page 17-17). 6. To install the oil seal (24), a governor shaft cap jig (Club Car Part No. 1014105) is required. Place the governor shaft cap jig on the governor arm shaft. Slide the new oil seal (24) over the tool until the oil seal contacts the transmission housing.
  • Page 305 10. Place the internal governor arm (7) around the internal governor arm alignment tool. Install the two screws (6) with a drop of thread locking adhesive. Torque screws to 26 in.lbs. (35 N-m). Remove the internal governor arm alignment tool (Figure 17-37). NOTE •...
  • Page 306 Assembly of the Transmission, Continued: 3. Use a 5/32 inch (4 millimeters) punch to carefully drive the roll pin (66) through shifter arm lever (67) and shifter shaft (22) (Figure 17-41). CAUTION • DO NOT ALLOW THE PUNCH TO STRIKE THE TRANSMISSION HOUSING. 4.
  • Page 307 11. Using a depth gauge, measure the distance from the gasket surface of the housing to the side of gear (62) on the input shaft (Figure 17-43). Use the table to determine which thrust washer to use. MEASURED DISTANCE INCHES (MILLIMETERS) THRUST WASHER CLUB CAR PART NO. Less than .1260 inches (3.2 millimeters) 1012723 More than .1260 inches (3.2 millimeters) but less than .1378 inches (3.5 millime-...
  • Page 308: Forward And Reverse Shifter Cable

    Installation of the Transmission, Continued: 5. Install driven clutch and key on transmission input shaft (See Torque Converter - Section 16). 6. Install 5/16 x 1” bolt with lockwasher and flatwasher and torque to 12-14 ft. lbs. (16/19 N-m) (Figure 17- 4, Page 17-4).
  • Page 309 1. Remove the ball joint socket (2) from the forward and reverse shifter assembly ball stud (3). 2. Remove the ball joint socket (2) from the shifter arm ball stud (19) on the transmission (Figure 17-46) (See Figure 17-5, Page 17-4). 3.
  • Page 310 Installation of the Forward and Reverse Shifter Cable, Continued: 5. Install the ball joint socket (2) on the forward and reverse shifter assembly ball stud (3) (Figure 17-46, Page 17-23). ADJUSTMENT OF THE FORWARD AND REVERSE SHIFTER CABLE With the shifter lever of the transmission (20) in neutral (straight up), the forward and reverse handle (21) should be straight up.
  • Page 311: Rear Suspension - Gasoline Vehicle

    GASOLINE VEHICLE GENERAL INFORMATION The rear suspension of the DS gasoline vehicle is completely independent. It consists of two mono-leaf springs controlled by two shock absorbers mounted between the springs and the vehicle frame. The engine is mounted on an inner-frame that moves with the rear suspension. A snubber, mounted on the front of the inner-frame and contained by brackets on the vehicle frame, controls inner-frame motion.
  • Page 312 Inspecting and Removing Shock Absorbers, Continued: FIGURE 18-1 2. To remove a shock absorber, remove the nut (5), cup washer and rubber bushing (Item 7) from the shock absorber stem (Figure 18-1). 3. Remove the nut (14) and washer (15) from the lower mounting stud (Figure 18-1). 4.
  • Page 313: Mono-Leaf Springs

    MONO-LEAF SPRINGS REMOVING THE MONO-LEAF SPRINGS 1. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jackstands under the frame cross-member between the spring mount and the side stringer, just forward of each rear wheel.
  • Page 314: Installing The Mono-Leaf Springs

    INSERT PRY BAR BETWEEN BOTTOM OF BRAKE HOUSING (A) AND SPRING RETAINER PLATE (B). LIFT PRY BAR UP TO SEPARATE AXLE TUBE (C) FROM SPRING (D) FIGURE 18-4 FIGURE 18-5 INSTALLING THE MONO-LEAF SPRINGS 1. To install the springs, reverse the removal procedure. See CAUTION below. CAUTION •...
  • Page 315 3. Place the jack under the transaxle and raise the vehicle enough to remove the jackstands. Lower the vehicle. • Keep axle nuts and wheel mounting nuts properly torqued. • Keep the front end aligned and properly adjusted. TYPICAL 4 PLACES yy yy yyyy yy y...
  • Page 316 Page 18-6...
  • Page 317: General Information

    SECTION 19 A - ELECTRICAL SYSTEM V-GLIDE 36 VOLT VEHICLE DANGER • BATTERIES RELEASE EXPLOSIVE GASES! KEEP ALL SOURCES OF IGNITION (CIGA- RETTES, SPARKS, FLAMES) AWAY FROM CHARGING AND SERVICE AREAS. CHARGING AND SERVICE AREAS SHOULD BE WELL-VENTILATED TO PREVENT BUILDUP OF EXPLO- SIVE GASSES.
  • Page 318 The Control Circuit, Continued: FRONT OF CAR POS. POS. NEG. NEG. NEG. NEG. POS. POS. DISCONNECT HERE V-GLIDE 36 VOLT ELECTRIC VEHICLE FIGURE 19-1 The key switch is an ON-OFF type, the function of which is to disable (open the control circuit) when the vehi- cle is not in use.
  • Page 319 BULLET CONNECTOR SPEED SWITCH BATTERY BANK RESISTOR BOARD TYPICAL 5 PLACES MOTOR FIGURE 19-2 Page 19-3...
  • Page 320 The on-board receptacle fuse link provides additional protection for the vehicle charging circuit. The fuse is rated for use with a Club Car Accu-Power Charger only. If it is blown, the cause should be determined before the fuse is replaced. A vehicle with a blown fuse will not charge (See Page 23-21, Accu-Power Battery Charger - Section 23A).
  • Page 321: Troubleshooting

    TROUBLESHOOTING V-GLIDE TROUBLESHOOTING GUIDE SYMPTOM PROBLEM POSSIBLE CAUSES REFER TO 1. 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 Limit 1) Loose wires.
  • Page 322 V-GLIDE TROUBLESHOOTING GUIDE SYMPTOM PROBLEM POSSIBLE CAUSES REFER TO 4. Vehicle runs slow, continued: Batteries 1) Loose terminals or corrosion. Test Procedure 1 and Batter- ies, Section 22, Page 22-5 2) Improperly wired. 3) Batteries failed. 4) Batteries not fully charged. Accelerator Push Rod 1) Accelerator rod is improperly V-Glide Wiper Switch,...
  • Page 323 BULLET CONNECTOR SPEED SWITCH BATTERY BANK RESISTOR BOARD TYPICAL 5 PLACES MOTOR FIGURE 19-4 Page 19-7...
  • Page 324: Circuit Testing

    The numbers on the probe symbols indicate test proce- dure 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 325 BULLET CONNECTOR SPEED SWITCH BATTERY BANK RESISTOR BOARD TYPICAL 5 PLACES MOTOR FIGURE 19-5 Page 19-9...
  • Page 326 WARNING • WHEN MAKING ELECTRICAL TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. - REMOVE THE KEY. - PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL. - DISCONNECT THE BATTERIES AS SHOWN (FIGURE 19-1, PAGE 19-2). •...
  • Page 327 2. If the reading is incorrect at either lever position, check the wires and terminals. If no problems are found with the wires or terminals, replace the switch (See Forward and Reverse Anti-arcing Limit Switch, Page 19-19). Test Procedure 4 - Accelerator Pedal Limit Switch 1.
  • Page 328 Test Procedure 7 - Forward and Reverse Switch 1. Use a continuity tester or a VOM set to Ω to test the forward and reverse switch in both directions: 1.1. With the forward and reverse switch in the forward position, place the red (+) probe on the com- mon terminal of the switch, and place the black (-) probe on the terminal of the heavy purple wire on the forward and reverse rotor (Figure 19-7).
  • Page 329 Test Procedure 9 - Solenoid Contacts (Power Off) WARNING • WHEN MAKING ELECTRICAL TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. - REMOVE THE KEY. - PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL. - DISCONNECT THE BATTERIES AS SHOWN (FIGURE 19-1, PAGE 19-2). •...
  • Page 330 Test Procedure 10, Continued; See DANGER on preceding page: WARNING • LIFT ONLY ONE END OF A 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.
  • Page 331 2. Remove the V-Glide Wiper Switch cover and observe the wiper arm brush as it moves across the fixed contacts. There should be sufficient spring pressure in the arm to keep the wiper arm brush firmly against each of the fixed contacts as it travels across them. There should also be proper surface con- tact between the wiper arm brush and each of the fixed contacts as shown (Figure 19-9).
  • Page 332 Page 19-16...
  • Page 333 SECTION 19B - ELECTRICAL COMPONENTS V-GLIDE 36 VOLT VEHICLE DANGER • WEAR A FULL FACE SHIELD WHEN WORKING AROUND BATTERIES BECAUSE OF THE DANGER OF AN EXPLODING BATTERY. • BATTERY - EXPLOSIVE GASSES - DO NOT SMOKE! KEEP SPARKS, FLAMES, CIGARETTES AWAY.
  • Page 334: 19B

    Electrical Components, Continued: WARNING • TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE, DISCONNECT BATTERIES AS SHOWN IN FIGURE 19-1, PAGE 9-2. KEY SWITCH The key switch is mounted just to the right of the steering column on the center dash panel. Testing the Key Switch See Test Procedure 2, Page 19-10.
  • Page 335: Forward And Reverse Anti-Arcing Limit Switch

    • On vehicles manufactured prior to December 19, 1994 (serial numbers lower than 9522-436452), hold the key switch and use the switch tool (Club Car Part No. 1012801) to turn the switch retaining nut on the outside of the dash panel.
  • Page 336: Accelerator Pedal Limit Switch

    Forward and Reverse Anti-arcing Limit Switch, Continued: See DANGER and WARNING on previous page. The Forward and Reverse Anti-arcing Limit Switch is located on the forward and reverse switch and is acti- vated by a cam on the forward and reverse switch rotor. Testing the Anti-arcing Limit Switch See Test Procedure 3, Page 19-10.
  • Page 337: The Reverse Buzzer

    Installing the Accelerator Pedal Limit Switch, Continued: 3. Connect the green wire to the normally closed (NC) terminal and the black wire to the common (COM) terminal of the limit switch. The normally open (NO) terminal should have no wire attached to it. 4.
  • Page 338: The Solenoid

    Testing the Reverse Buzzer Circuit, Continued: 4.4. Pull center dash out approximately one inch from the frame and then bend the top right corner of the dash panel inward while pulling the top of the panel out and down. NOTE •...
  • Page 339: Resistors

    The Solenoid, Continued: WARNING • WHEN MAKING ELECTRICAL TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. - REMOVE THE KEY. - PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL. - DISCONNECT THE BATTERIES AS SHOWN (FIGURE 19-1, PAGE 19-2). •...
  • Page 340 • IF A 3 1/2 HORSEPOWER MOTOR IS BEING USED IN CONJUNCTION WITH A V-GLIDE WIPER SWITCH, THE FOURTH AND FIFTH SPEED RESISTOR COILS MUST BE REPLACED WITH NEW COILS (CLUB CAR PART NO.S 1014654 AND 1014655). FIGURE 19-13 Page 19-24...
  • Page 341: V-Glide Wiper Switch

    NOTE • MAKE SURE THAT NO RESISTOR COIL IS TOUCHING ANOTHER ONE. THE VEHICLE WILL NOT RUN PROPERLY IF ANY COILS ARE TOUCHING. • MAKE SURE THAT THE RESISTOR COILS ARE INSTALLED IN THE PROPER ORDER (FIGURE 19-13, PAGE 19-24). RESISTOR 1 HAS THE SMALLEST DIAMETER WIRE AND THE GREAT- EST NUMBER OF COILS.
  • Page 342 V-Glide Wiper Switch, Continued: WIPER ARM BRUSH AND FIXED CONTACTS SHOULD SEAT FIRMLY AGAINST EACH OTHER WIPER FIXED BRUSH CONTACT CORRECT INCORRECT INCORRECT FIGURE 19-14 V-Glide Wiper Switch Arm Adjustment The contact surfaces on the wiper switch arm brush and the fixed contacts must be parallel to ensure effi- cient operation of the V-Glide wiper switch (See Figure 19-14).
  • Page 343 TYPICAL 8 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES MOUNTING DETAIL FIGURE 19-15 V-Glide Wiper Switch Adjustment Each of the adjustments in the following WARNING (top of page 19-28) affects V-Glide wiper switch adjust- ment. To ensure proper wiper switch adjustment, all of these items must be properly adjusted. If any one of them requires adjustment, all of them must be checked, and also adjusted if necessary, in the order listed in the WARNING at the top of page 19-28.
  • Page 344 V-Glide Wiper Switch Adjustment, Continued: WARNING • TO PROPERLY ADJUST YOUR WIPER SWITCH, CHECK, AND ADJUST IF NECESSARY, THE FOLLOWING ITEMS IN THE ORDER LISTED: - BRAKE PEDAL AND CABLE ADJUSTMENT. SEE SECTION 6. - ACCELERATOR ROD ADJUSTMENT. SEE SECTION 6. - ACCELERATOR PEDAL STOP ADJUSTMENT.
  • Page 345 WARNING • WHEN MAKING ELECTRICAL TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. - REMOVE THE KEY. - PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL. - DISCONNECT THE BATTERIES AS SHOWN (FIGURE 19-1, PAGE 19-2). 1.
  • Page 346 V-Glide Wiper Switch Assembly, Continued: 6. If the ball stud (5) was removed, insert it through the bell crank with the ball facing away from the wiper switch housing and install the lock nut (7). While holding the ball stud with a wrench, tighten the lock nut to 4-5 ft.lbs.
  • Page 347 2. Install the accelerator rod onto the ball stud. 3. Connect the 18 gauge green wire from the limit switch to the rear small post on the solenoid (Figure 19-2, Page 19-3). 4. Connect the 18 gauge black wire to black lead from charger receptacle (Figure 19-16, Page 19-30). 5.
  • Page 348: Forward And Reverse Switch

    FORWARD AND REVERSE SWITCH WARNING • WHEN MAKING ELECTRICAL TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. - REMOVE THE KEY. - PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL. - DISCONNECT THE BATTERIES AS SHOWN (FIGURE 19-1, PAGE 19-2). •...
  • Page 349 2. Remove the screws (11) and nuts (12) that mount the forward and reverse switch to the body (Figure 19-17). 3. Pull the forward and reverse switch away from the body and out of the battery compartment for ease of service.
  • Page 350 Page 19-34...
  • Page 351: Electrical System - Powerdrive System

    SOUNDING, THE CONTROLLER IS DISCHARGED. 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 serial number A9529-445799, uses a continuously variable potentiometer. Both versions feature a 48 volt electrical system, including an on-board computer that controls the battery charger, monitors vehicle energy usage, and provides test data to the optional Communication Display Module.
  • Page 352: The On-Board Computer

    Battery Warning Light, see Section 23, Page 23-28). OBC data can also be useful in performing 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 20-22).
  • Page 353 # 18 RED / WHITE FIGURE 20-2 Page 20-3...
  • Page 354 # 18 RED / WHITE FIGURE 20-3 Page 20-4...
  • Page 355 THE CONTROL CIRCUIT The control circuit consists of the key switch, F&R (Forward and Reverse) anti-arcing limit switch, accelerator limit switch, solenoid, and connecting wires. The key switch is an ON-OFF type, the function of which is to disable, or open, the control circuit when the vehicle is not in use.
  • Page 356: Troubleshooting Guide

    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, Page 20-36).
  • Page 357 POWERDRIVE SYSTEM 48 TROUBLESHOOTING GUIDE SYMPTOM PROBLEM POSSIBLE CAUSES REFER TO 1. 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 Limit 1) Loose wires.
  • Page 358 POWERDRIVE SYSTEM 48 TROUBLESHOOTING GUIDE SYMPTOM PROBLEM POSSIBLE CAUSES REFER TO 3. Vehicle runs slowly. Wiring 1) Improperly wired. Figure 20-2 or 20-3, Page 20-3 or 20-4 Batteries 1) Loose terminals or corrosion. Test Procedure 1, and Batteries, Section 22 2) Improperly wired.
  • Page 359: 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 360 # 18 RED / WHITE FIGURE 20-5 Page 20-10...
  • Page 361 # 18 RED / WHITE FIGURE 20-6 Page 20-11...
  • Page 362 CONTROL CIRCUIT WARNING • WHEN MAKING ELECTRICAL TESTS OR REPAIRS, ALWAYS: - WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION. - REMOVE THE KEY. - PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL. - DISCONNECT THE BATTERIES AS SHOWN (FIGURE 20-1, PAGE 20-2). •...
  • Page 363 Test Procedure 3 - Forward/Reverse Anti-Arcing Limit Switch: NOTE NOTE NOTE • THERE ARE THREE LIMIT SWITCHES ON THE FORWARD AND REVERSE SWITCH. THE FOR- WARD AND 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 364 # 18 RED / WHITE FIGURE 20-7 Page 20-14...
  • Page 365 # 18 RED / WHITE FIGURE 20-8 Page 20-15...
  • Page 366 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 20-2, Page 20-3, or Figure 20-3, Page 20-4). 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 367 SPEED CONTROL CIRCUIT Test Procedure 8 - Multi-step Potentiometer: 1. Disconnect the black and white 18 gauge wires that are attached to controller terminals “2” and “3” (ter- minals “B” and “C” on early model vehicles) (see wiring diagram Figure 20-2, Page 20-3 to identify terminals) and connect ohm meter to wires.
  • Page 368 Test Procedure 10 - Solid State Speed Controller: DANGER • TURN THE KEY TO OFF, PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL, AND DIS- CONNECT THE BATTERY CABLES AS SHOWN IN FIGURE 20-1, PAGE 20-2. FAILURE TO DO SO MAY CAUSE THE VEHICLE TO RUN OVER YOU, RESULTING IN SEVERE INJURY OR DEATH.
  • Page 369 2.1. Remove 6 gauge white wire from A2 motor terminal and secure it so that it will not make contact with any live components or connections. 2.2. Reconnect batteries (Figure 20-1, Page 20- 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.
  • Page 370 BLIES SHOULD BE CHECKED FOR MOISTURE CONTAMINATION. • IT IS STRONGLY RECOMMENDED THAT THESE EARLY FUSE CONFIGURATIONS BE REPLACED WITH THE CURRENT WATERPROOF FUSE HOLDER ASSEMBLY (CLUB CAR PART NO. 1018963-02). 3. It is possible that the On-board Computer can become “locked up”, causing the OBC solenoid lockout circuit to malfunction.
  • Page 371 Test Procedure 12 - Half-speed Reverse Limit Switch (F&R Limit Switch No. 3): 1. Check for proper wiring (Figure 20-6 or 20-8) and tight connections. 2. Using a continuity tester or VOM set to ohms, check continuity across common (COM) and normally open (NO);...
  • Page 372: The Communication Display Module (Cdm)

    Energy units removed since last charge cycle. Func3 - Total accumulated energy units removed. Func4 - Last charge termination type (1 = Incomplete, 2 = DVDT, 4 = Normal, 8 = Max. timer). POWER Club Car PART #17075 FIGURE 20-11 Page 20-22...
  • Page 373 NOTE • THE VALUES OF ALL FOUR FUNCTIONS CAN BE RECALLED BY PRESSING AND RELEASING THE CDM BUTTON. 45° Club Car BODY OF CDM SHOULD BE POSITIONED POSITION CDM SO THAT IT IS ALIGNED AT APPROXIMATELY 45° TO GRADE DIRECTLY BEHIND THE ON-BOARD COMPUTER...
  • Page 374: Communication Display Module Troubleshooting Guide

    COMMUNICATION DISPLAY MODULE TROUBLESHOOTING GUIDE Use this chart as a starting point for troubleshooting problems with communications between the CDM and on-board computer. Contact your Club Car representative for more comprehensive information. OBC Will Not Communicate With The CDM Dead CDM battery...
  • Page 375: The Key Switch

    SECTION 20 B - ELECTRICAL COMPONENTS, POWERDRIVE SYSTEM 48 VEHICLE DANGER • BATTERY - EXPLOSIVE GASES! DO NOT SMOKE. KEEP SPARKS AND FLAMES AWAY. VEN- TILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE. ALWAYS WEAR FULL FACE SHIELD WHEN WORKING ON OR NEAR BATTERIES. •...
  • Page 376 • On vehicles manufactured prior to December 19, 1994 (serial numbers lower than 9522-436452), hold the key switch and use the switch tool (Club Car Part No. 1012801) to turn the switch retaining nut on the outside of the dash panel.
  • Page 377: Forward And Reverse Switch

    FORWARD AND REVERSE SWITCH DANGER • TURN THE KEY TO OFF, PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL, DISCON- NECT THE BATTERY CABLES AS SHOWN IN FIGURE 20-1, PAGE 20-2, AND DISCHARGE THE CONTROLLER (SEE WARNING ON PAGE 20-1). FAILURE TO DO SO MAY CAUSE THE VEHI- CLE TO RUN OVER YOU, RESULTING IN SEVERE INJURY OR DEATH.
  • Page 378: Forward And Reverse Limit Switches

    FORWARD AND REVERSE (F&R) LIMIT SWITCHES The F&R anti-arcing limit switch, reverse buzzer limit switch, and reverse half-speed limit switch are located on the F&R switch and are activated by a cam on the F&R switch rotor (Figure 20-14). Testing the Limit Switches 1.
  • Page 379: The Reverse Buzzer

    1. Using the wire stripper/crimper, strip the wire from the harness back 1/4 inch (5.6 mm ). 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 380 The Reverse Buzzer, Continued: Testing the Reverse Buzzer Circuit 1. Disconnect the red/white wire from F&R limit switch No. 2 and connect the black probe of a multimeter (set to volts) to the wire. Place the red probe of the multi-meter on the positive post of battery No. 1. The multimeter should show battery voltage.
  • Page 381: The Solenoid

    NOTE NOTE • BENDING THE TOP RIGHT CORNER OF THE CENTER DASH INWARD WHILE REMOVING IT WILL PREVENT THE CONTACTS ON THE REAR OF THE KEY SWITCH FROM TOUCHING THE METAL FRAME AROUND THE DASH. 3. Slide center dash panel up the steering column by snapping out the top and then rotating the panel out and up.
  • Page 382 The Solenoid, Continued: Installing the Solenoid 1. Install the solenoid to the mounting plate and torque to 66 in.lbs. (7.5 N-m). The solenoid does not have to be oriented in any particular manner. 2. Install wires on the solenoid as shown in the wiring diagram (Figure 20-2, Page 20-3, or Figure 20-3, Page 20-4).
  • Page 383: On-Board Computer

    2. Discharge the controller (See instructions in Warning Box on Page 20-25). WARNING • FAILURE TO DISCHARGE THE CONTROLLER COULD RESULT IN A SHORT CIRCUIT SHOULD THE WRENCH OR RATCHET TOUCH THE LARGE POST DURING REMOVAL OR INSTALLA- TION OF THE RESISTOR ASSEMBLY. 3.
  • Page 384: Solid State Speed Controller

    CHARGER RECEPTACLE BLACK BUTYL MATERIAL 10 GAUGE BLACK WIRE TO OBC TERMINAL LOCK NUTS GREY WIRE 10 GAUGE BLACK FUSE ASSEMBLY FROM OBC GREY LEAD WITH 6 GAUGE BLACK MALE CONNECTOR FIGURE 20-15 FIGURE 20-16 5. Remove the 18 gauge red and yellow wires on the solenoid. 6.
  • Page 385 D.C. CORDSET SEAT SUPPORT FRONT PANEL FIGURE 20-17 Removing the Receptacle 1. Remove the 10 gauge red wire (4) from the positive post of battery No. 1, and then pull the 10 gauge red wire to the receptacle (2) (Figure 20-17). 2.
  • Page 386: Receptacle Fuse Link

    Installing a New Receptacle, Continued: 4. Attach the 10 gauge black wire from the on-board computer to the fuse assembly using a ratchet and a 3/8” socket (See Figure 23-20, Page 23-29). 5. Connect 1/4” connector on the 10 gauge grey wire (3) from the charger receptacle to the 18 gauge grey wire from the on-board computer.
  • Page 387: Continuously Variable Potentiometer

    CONTINUOUSLY VARIABLE POTENTIOMETER Testing the Continuously Variable Potentiometer See Test Procedure 9, Page 20-17. Removing the Continuously Variable Potentiometer (Figure 20-18, Page 20-38) 1. Disconnect batteries (Figure 20-1, Page 20-2). 2. Discharge the controller (See instructions in Warning Box on Page 20-25). WARNING •...
  • Page 388 Removing the Continuously Variable Potentiometer, Continued: TO WIRE HARNESS FIGURE 20-18 15. Remove the four 1/4 inch bolts (17), washers, and nuts attaching the potentiometer housing (18) and the pivot rod support (19) to the frame (Figure 20-18). 16. Remove the potentiometer housing and pivot rod support from the I-Beam. Installing the Continuously Variable Potentiometer (Figure 20-18) 1.
  • Page 389 NOTE NOTE • MAKE SURE THAT THE ACTUATOR LEVER PIN IS INSERTED INTO THE POTENTIOMETER LEVER. SEE FIGURE 20-19. ACTUATOR LEVER PIN POTENTIOMETER LEVER FIGURE 20-19 3. Now tighten the four 1/4 inch potentiometer housing mounting bolts to between 70 and 80 in.lbs (8.0/ 9.0 N-m).
  • Page 390: Multi-Step Potentiometer

    MULTI-STEP POTENTIOMETER DANGER • TURN THE KEY TO OFF AND REMOVE THE KEY, PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL, DISCONNECT THE BATTERY CABLES AS SHOWN IN FIGURE 20-1, PAGE 20-2, AND DISCHARGE THE CONTROLLER (SEE WARNING ON PAGE 20-1). FAILURE TO DO SO MAY CAUSE THE VEHICLE TO RUN OVER YOU, RESULTING IN SEVERE INJURY OR DEATH! WARNING •...
  • Page 391: Battery Warning Light

    5. Connect the 18 gauge green/white wire to F&R limit switch No. 1. Connect the 18 gauge black (2), white (3), and blue (4) wires to the multi-step potentiometer. See Figure 20-2, Page 20-3 for proper wir- ing connections. 6. Connect the accelerator rod (1) to the potentiometer. 7.
  • Page 392 Removing the Battery Warning Light, Continued: NOTE NOTE • BENDING THE TOP RIGHT CORNER OF THE CENTER DASH INWARD WHILE REMOVING IT WILL PREVENT THE CONTACTS ON THE REAR OF THE KEY SWITCH FROM TOUCHING THE METAL FRAME AROUND THE DASH. 2.5.
  • Page 393: General Information

    SECTION 21A - ELECTRICAL SYSTEM, POWERDRIVE PLUS VEHICLES DANGER • THE BATTERY WIRES MUST REMAIN CONNECTED WHILE PERFORMING SOME TEST PRO- CEDURES. RAISE THE REAR END OF THE VEHICLE AND SUPPORT IT ON JACKSTANDS, WITH THE REAR WHEELS OFF THE GROUND, WHILE PERFORMING ALL TEST PROCE- DURES.
  • Page 394 BATTERY BANK ENERGY DISPLACEMENT MODULE SPADE CONNECTOR MOTOR FIGURE 21-1 Page 21-2...
  • Page 395 General Information, Continued: • “Zero Speed Detect”: This prevents the vehicle from rolling away uncontrolled should a driver park on a slope and leave the vehicle without locking the park brake. When the vehicle is in use with the key switch ON, the zero speed detect function will resist vehicle rolling.
  • Page 396 Z PLUG CONNECTIONS DIRECTION OF CURRENT Positive (+) To Negative (-) Green/White Wire from With key switch ON and accelerator pedal depressed, Z8 Potentiometer Limit transistor completes the circuit from potentiometer limit switch Switch through green/white wire to controller, which actuates the controller and starts the vehicle.
  • Page 397: The Control Circuit

    OR A VOLT/OHM METER (VOM) CAPABLE OF READING FROM 0-48 VOLTS DC. THE VOLT OHM METER (CLUB CAR PART NO. 1011480), CALIBRATION TEST MODULE (CTM) (CLUB CAR PART NO. 1018871-01) AND CONTINUITY TESTER (CLUB CAR PART NO. 1011273) ARE AVAIL- ABLE FROM YOUR LOCAL AUTHORIZED DEALER OR FROM CLUB CAR SERVICE PARTS.
  • Page 398 Capacitor Charge Circuit, Continued: DIRECTION OF CURRENT ACCELERATOR LIMIT SWITCH POTENTIOMETER ON-BOARD COMPUTER MOTOR SPEED SENSOR Z10 Z11 Z12 Z13 FORWARD AND REVERSE SWITCH SOLENOID CONTROL VOLTAGE SUPPLY FOR REGENERATIVE FUNCTIONS VOLTAGE SUPPLY TO CONTROLLER CAPACITORS FIGURE 21-5 NOTE • THE FOLLOWING CONDITIONS MUST EXIST FOR THE CAPACITOR CHARGE CIRCUIT TO WORK PROPERLY: - THE 6 GAUGE BLACK WIRE FROM THE NEGATIVE (-) TERMINAL OF BATTERY NO.
  • Page 399 BATTERY BANK FIGURE 21-6 MAIN SOLENOID CONTROL CIRCUIT (FIGURE 21-7, PAGE 21-8) The Main Solenoid Control Circuit supplies voltage to the solenoid activating coil. When the key switch is turned to the ON position and the two second (20 seconds on some early models) time delay transistor in the speed controller is on, the circuit is complete and the main solenoid coil is activated, closing the solenoid power contacts.
  • Page 400 Main Solenoid Control Circuit, Continued: BATTERY BANK FIGURE 21-7 FORWARD AND REVERSE CONTROL CIRCUIT (FIGURE 21-8) The Forward and Reverse Control Circuit controls the selection of either forward or reverse vehicle move- ment. The Forward and Reverse Control Circuit consists of: •...
  • Page 401 wire or blue wire, depending on the position of the rocker switch. When operating the vehicle in forward, the white wire supplies voltage from the rocker switch No. 3 terminal to the Z6 position on the Z plug/controller. When operating the vehicle in reverse, the blue wire supplies voltage from the rocker switch No. 1 terminal to the controller Z7 position.
  • Page 402 Controller Activating Circuit, Continued: With the key switch in the ON position, the forward and reverse rocker switch in forward or reverse, and the accelerator pedal depressed, voltage is supplied to the Z8 position in the controller. This activates the con- troller which completes the circuit, supplying voltage to the motor.
  • Page 403 BATTERY BANK FIGURE 21-10 SPEED CONTROL CIRCUIT (FIGURE 21-11) The ground speed of the vehicle is regulated by the input voltage supplied to the motor by the controller. Although the motor operates on 48 volt input at both low and high speeds, the controller regulates ground speed of the vehicle by shortening or lengthening the pulses to the motor.
  • Page 404 Speed Control Circuit, Continued: The potentiometer detects accelerator pedal position and sends a corresponding voltage signal to the con- troller. As the accelerator pedal is depressed, voltage from the potentiometer changes, causing the controller to send longer pulses to the motor and thereby increasing vehicle speed. The Speed Control Circuit Consists of: •...
  • Page 405 DYNAMIC BRAKING SOLENOID CONTROL CIRCUIT (FIGURE 21-13) The Dynamic Braking Control Circuit directs the current that is generated by the motor to either the batteries or the dynamic braking resistor coil (energy displacement module). When the batteries are at or near full charge, the dynamic braking solenoid will shut off when the motor is generating energy, sending the current to the resistor coil.
  • Page 406 On-Board Computer (OBC) Control Circuit, Continued: • When the batteries can accept a regenerative charge, the OBC sends a signal through the Z 11 (green wire) position to the controller, to switch from dynamic braking to regenerative braking. • When the battery charger DC cord is plugged into the charger receptacle, the OBC will shut off current to the Z12 (yellow wire) transistor in the controller, and this activates the solenoid lock-out feature.
  • Page 407 • Batteries have discharged to less than 25% of rated capacity. • If AC power is interrupted during the charge cycle, the light will turn on and remain on as long as the DC cord is plugged in. This indicates that the batteries did not receive a full charge. The light will go out when AC power is restored or the DC cord is unplugged.
  • Page 408: The Power Circuit

    FIGURE 21-16 THE POWER CIRCUIT During normal vehicle operation, the function of the power circuit is to supply electrical current from the bat- tery pack to the motor. When motor braking is activated, the power circuit will direct motor generated current to either the batteries or the energy displacement module, depending on the battery pack state of charge (See Figure 21-17).
  • Page 409 BATTERY BANK ENERGY DISPLACEMENT MODULE MOTOR FIGURE 21-17 ELECTRIC MOTOR The PowerDrive Plus vehicle uses a 48 volt shunt wound motor rather than the series wound motor that is standard in other vehicles. A shunt wound motor is able to vary the amount of current passing through its field coils while, at the same time, maintaining a constant current flow through its armature.
  • Page 410 The Power Circuit - Motor Braking, Continued: BATTERY BANK MOTOR FIGURE 21-18 • Regenerative Braking Current produced by the motor travels from the A2 terminal on the motor through a 6 gauge white wire to the dynamic braking solenoid. If the batteries have discharged to the point that they can accept a regenerative charge from the motor, the dynamic braking solenoid will remain closed (there will be con- tinuity across the large posts) and the current will continue from the dynamic braking solenoid to the controller through another 6 gauge white wire, and then on to the batteries through a 6 gauge black...
  • Page 411: The Charge Circuit

    MOTOR ENERGY DISPLACEMENT MODULE DYNAMIC MOTOR BRAKING CIRCUIT FIGURE 21-19 THE CHARGE CIRCUIT The charge circuit consists of the on-board computer, battery charger, DC charger plug, charger receptacle, receptacle fuse link, and the 8-volt batteries (Figure 21-20). The batteries and the battery charger will be dis- cussed in separate sections in this manual (Batteries - Section 22, and Battery Charger - Section 23).
  • Page 412: Troubleshooting Guide

    TROUBLESHOOTING GUIDE TESTING THE Z-PLUG FOR CONTINUITY AND VOLTAGE INPUT AND OUTPUT Test procedures begin on page 21-25. TEST Z-PLUG POSITION Red wire voltage input to controller Red wire continuity Orange/white wire voltage input to controller Orange/white wire continuity Blue/white wire voltage output from controller Blue/white wire continuity Brown wire voltage output from controller Brown wire continuity...
  • Page 413 Page 21-21...
  • Page 414 Page 21-22...
  • Page 415 Page 21-23...
  • Page 416 Page 21-24...
  • Page 417: Test Procedures

    TEST PROCEDURES NUMERICAL LISTING OF TEST PROCEDURES (Test Procedures begin on page 21-26.) 1. Battery Pack Voltage 2. Individual Battery Voltage 3. Battery Pack with Low Voltage 4. Voltage at Z1 Position in Z Plug 5. Z1 Red Wire Continuity 6.
  • Page 418 Numerical Listing of Test Procedures, Continued: 42. Motor Sensor 3-Wire Plug Connection 43. Z11 (Green Wire) and Z12 (Yellow Wire) Continuity TEST PROCEDURES Test Procedure 1 - Battery Pack Voltage 1. Turn the key switch to OFF and place the forward and reverse switch in NEUTRAL. Leave the batteries connected and leave the Z plug connected to the controller.
  • Page 419 Test Procedure 2 - Individual Battery Voltage 1. Turn the key switch to OFF and place the forward and reverse switch in NEUTRAL. Leave the batteries connected and leave the Z plug connected to the controller. 2. Place black (-) probe of a multimeter, set to Volts DC (DCV), on the negative (-) post of battery No. 1 and place red (+) probe on the positive (+) post of battery No.
  • Page 420 Test Procedure 4 - Z Plug Position Z1 Voltage Check 1. Turn the key switch to OFF and place the forward and reverse switch in NEUTRAL. Disconnect the Z plug from the controller. Leave the batteries connected. 2. Place the black (-) probe of a multimeter, set to Volts DC, on the negative (-) post of battery No. 6 and place the red (+) probe in the Z1 connector position in the Z Plug.
  • Page 421 1. Turn the key switch to OFF and place the forward and reverse switch in NEUTRAL. Leave the batteries connected and leave the Z plug connected to the controller. 2. Place the black (-) probe of a multimeter, set to Volts DC, on the negative (-) post of battery No. 6 and place the red (+) probe on the large post of the main solenoid (with 6 gauge yellow wire attached) (Fig- ure 21-25).
  • Page 422 Test Procedure 8 - Key Switch Continuity 1. Turn the key switch to OFF and place the forward and reverse switch in NEUTRAL. Disconnect the bat- teries. Leave the Z plug connected to the controller. 2. Place the black (-) probe of a multimeter, set to ohms (Ω), on the small post of the main solenoid (with the blue, red, and red/white wires attached) and place the red (+) probe on the large post of the main solenoid (with 6 gauge yellow wire attached) (Figure 21-27).
  • Page 423 DATA HOLD DATA HOLD AC/DC 500V MAX AC/DC 500V MAX 250V MAX 250V MAX AC V AC V DC V DC V KEY SWITCH KEY SWITCH FIGURE 21-29 FIGURE 21-30 3. Place the black (-) probe of a multimeter, set to Volts DC, on the small post of the main solenoid (with the blue/white wire attached) and place the red (+) probe on the positive (+) post of battery No.
  • Page 424 Test Procedure 11 - Z4 (Blue/White Wire) Continuity 1. Turn the key switch to OFF and place the forward and reverse switch in NEUTRAL. Disconnect the bat- teries and disconnect the Z plug from the controller. 2. Make sure the blue/white wire is in the Z4 position in the Z plug. Make sure the blue/white wire is con- nected to the terminal and that the terminal is properly inserted into the Z plug.
  • Page 425 CLICK BATTERY BANK BULLET CONNECTOR FIGURE 21-34 BLACK WIRE JUMPER WIRE BATTERY DATA HOLD BANK FORWARD AND AC/DC 500V MAX 250V MAX JUMPER WIRE REVERSE SWITCH AC V DC V FIGURE 21-35 FIGURE 21-36 Test Procedure 14 - Reverse Buzzer Circuit 1.
  • Page 426 Test Procedure 14 - Reverse Buzzer Circuit, Continued: 7. Remove the three mounting screws from the forward and reverse switch case and remove the case from the rear body. 8. Disconnect the 18 gauge black wire from the center terminal on the forward and reverse switch. 9.
  • Page 427 FORWARD AND REVERSE ROCKER SWITCH DATA HOLD YELLOW WIRE AC/DC 500V MAX 250V MAX TO THE OBC AC V DC V FUSE MALE BULLET FOR VEHICLES CONNECTOR PRIOR TO SERIAL NUMBER A9615-494279 FIGURE 21-39 FIGURE 21-40 SOLENOID RED WIRE DATA HOLD FUSE AC/DC 500V MAX 250V MAX...
  • Page 428 Test Procedure 15 - On-board Computer Red and Yellow Wire Fuses, Continued: • For vehicles with serial number A 9615-4942279 and later: The fuse that was on the yellow wire has been incorporated into the circuitry of the on-board computer. The fuse on the red wire is now located approximately six inches (15 cm) from the main solenoid and is in a yellow rubber housing.
  • Page 429 3. Place the black (-) probe of a multimeter, set to Volts DC, on the negative (-) post of battery No. 6 and place the red (+) probe in the Z7 (blue wire) connector position in the Z plug (Figure 21-44). Turn the key switch to ON and place the forward and reverse rocker switch in reverse;...
  • Page 430 Test Procedure 18 - Forward and Reverse Rocker Switch Continuity, Continued: 5. Place the black (-) probe of a multimeter, set to ohms (Ω), on the blue wire terminal end (that was removed from the rocker switch) and place the red (+) probe in the Z7 (blue wire) connector position in the Z plug.
  • Page 431 Test Procedure 20 - Accelerator Limit Switch Wire Continuity (Green/White and Blue Wires) 1. Turn the key switch to OFF and place the forward and reverse switch in NEUTRAL. Disconnect the bat- teries and disconnect the Z plug from the controller. 2.
  • Page 432 Test Procedure 22 - Voltage at Z3 (Orange/White Wire) Position In Z Plug 1. Turn the key switch to OFF and place the forward and reverse switch in NEUTRAL. Leave the batteries connected. Disconnect the Z plug from the controller. 2.
  • Page 433 Test Procedure 24 - Voltage to Dynamic Braking Solenoid Coil 1. Turn the key switch to OFF and place the forward and reverse switch in NEUTRAL. Leave the batteries connected and leave the Z plug connected to the controller. 2. Place the black (-) probe of a multimeter, set to Volts DC, on the negative (-) post of battery No. 6 and place the red (+) probe on the small post on the dynamic braking solenoid (with 18 gauge red and orange/white wires attached) (Figure 21-58).
  • Page 434 SPEED SENSOR TEST: SET MODE SWITCH TO "SSAM", CONNECT TEST SOCKET TO MOTOR SPEED SENSOR PLUG, ROTATE MOTOR. L.E.D. SHOULD PULSE ON AND OFF INDICATING SPEED SENSOR IS FUNCTIONAL. WIRE SEE OPERATING INSTRUCTIONS FOR MORE DETAIL POWER MODE Club Car SSAM GREEN WIRE FIGURE 21-63 FIGURE 21-64 Page 21-42...
  • Page 435 The energy displacement module is mounted on the vehicle frame, directly behind the batteries. 1. Raise the rear of the vehicle. WARNING • LIFT ONLY ONE END OF A 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.
  • Page 436 3-wire plug (Figure 21-64, Page 21-42). 3. Connect the Calibration Test Module (CTM) (Club Car Part No. 1018871-01) to the 3-wire plug from the potentiometer, and connect the green wire from the Calibration Test Module to the green/white wire from the accelerator switch.
  • Page 437 BATTERY BANK BATTERY BANK DATA HOLD DATA HOLD AC/DC 500V MAX AC/DC 500V MAX 250V MAX 250V MAX AC V AC V DC V DC V RED PROBE RED PROBE ON PURPLE ON YELLOW WIRE FEMALE WIRE FEMALE THREE WIRE THREE WIRE CONNECTION CONNECTION...
  • Page 438 Test Procedure 35 - 3-Wire Plug on the Potentiometer, Continued: 2. Inspect the wires in the 3-wire connector from the potentiometer. Make sure that wire connections are yellow to yellow, purple to purple, and black to white/black. 3. Disconnect the plug and inspect for broken wires at the pin terminals. Inspect the pins to make sure that they are secure in the plug.
  • Page 439 4. With the accelerator pedal in the UP position, the voltage reading should be zero. 5. Slowly depress the accelerator pedal. The first voltage reading should be approximately 5-10 volts and the rear wheels should turn slowly. As the accelerator pedal is depressed toward the floor, the voltage should continue to increase as the wheels turn faster.
  • Page 440 2. Disconnect the 3-wire plug at the motor speed sensor. 3. Connect the Calibration Test Module (CTM) (Club Car Part No. 1018871-01) to the motor speed sensor plug. It is not necessary to connect the green wire from the CTM to another wire.
  • Page 441 SOCKET TO MOTOR SPEED SENSOR PLUG, ROTATE MOTOR. L.E.D. SHOULD PULSE ON AND OFF INDICATING SPEED SENSOR IS FUNCTIONAL. DC V THREE WIRE CONNECTOR SEE OPERATING INSTRUCTIONS FOR MORE DETAIL POWER Club Car MODE SSAM MOTOR FIGURE 21-74 FIGURE 21-75...
  • Page 442 Test Procedure 41 - Z13 (Red Wire) and Z14 (Green Wire) Continuity 1. Turn the key switch to OFF and place the forward and reverse switch in NEUTRAL. Disconnect the bat- teries and disconnect the Z plug from to the controller. 2.
  • Page 443 7. Pull gently on the two halves of the plug connection to ensure that they are fastened securely. 8. Check wire positions in the 3-wire plug and make sure that wires of the same color mate when the plug is connected. 9.
  • Page 445: Key Switch

    SECTION 21B - ELECTRICAL COMPONENTS, POWERDRIVE PLUS VEHICLES DANGER • THE BATTERY WIRES MUST REMAIN CONNECTED WHILE PERFORMING SOME TEST PROCE- DURES. RAISE THE REAR END OF THE VEHICLE AND SUPPORT IT ON JACKSTANDS, WITH THE REAR WHEELS OFF THE GROUND, WHILE PERFORMING ALL TEST PROCEDURES. •...
  • Page 446: Forward And Reverse Switch

    Key Switch, Continued: Installing the Key Switch: See Installing the Key Switch, Page 20-26. FORWARD AND REVERSE SWITCH DANGER • TURN THE KEY TO OFF, PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL, AND DIS- CONNECT THE BATTERY CABLES AS SHOWN IN FIGURE 21-2, PAGE 21-3. FAILURE TO DO SO MAY CAUSE THE VEHICLE TO RUN OVER YOU, RESULTING IN SEVERE INJURY OR DEATH.
  • Page 447: Main Solenoid

    MAIN SOLENOID MAIN SOLENOID DYNAMIC BRAKING SOLENOID DYNAMIC BRAKING MAIN SOLENOID SOLENOID SOLENOID SOLENOID MOUNTING MOUNTING FIGURE 21-82 FIGURE 21-83 The solenoid is located on the passenger’s side outside of the frame 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 (acti- vating coil posts).
  • Page 448: Dynamic Braking Solenoid

    Installing the Solenoid, Continued: 2. Install the wires on the solenoid as shown in wiring diagram (Figure 21-1, Page 21-2). DYNAMIC BRAKING SOLENOID The solenoid is located on the passenger’s side inside of the frame behind the battery compartment. The solenoid has two sets of posts;...
  • Page 449: Controller

    3. Disconnect the gray wire (from the OBC) at the sense lead fuse, leaving the sense lead fuse connected to the gray lead from the charger receptacle (Figure 21-1, Page 21-2). 4. Remove the 18 gauge red wire on the solenoid. 5.
  • Page 450: Charger Receptacle

    Removing the Controller 1. Disconnect the Batteries (Figure 21-2, Page 21-3). 2. Remove all the 6 gauge wires connected to the controller. Remove the four wires from the B- on the controller. Remove the 10 gauge blue wire from the controller. 3.
  • Page 451 FIGURE 21-85 Page 21-59...
  • Page 452 Page 21-60...
  • Page 453: General Information

    SECTION 22 - BATTERIES DANGER • BATTERY - EXPLOSIVE GASES! DO NOT SMOKE. KEEP SPARKS AND FLAMES AWAY. VEN- TILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE. ALWAYS WEAR FULL FACE SHIELD AND RUBBER GLOVES WHEN WORKING ON BATTERIES. •...
  • Page 454 General Information, Continued: MOTOR PbO 2 H SO BATTERY IN USE (DISCHARGING) CHARGED BATTERY FIGURE 22-1 FIGURE 22-2 CHARGER PbSO 4 PbSO DISCHARGED BATTERY BATTERY CHARGING FIGURE 22-3 FIGURE 22-4 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.
  • Page 455: Common Misconceptions About Batteries

    creating electrical shorts. It must be porous enough to allow charged ions to pass through between the posi- tive and the negative plates, but never allow the two materials to contact each other. Whenever two unlike metals are immersed in an acid solution, an electric current is generated. In a “deep cycle”...
  • Page 456: Replacing Batteries

    REPLACING BATTERIES DANGER • BATTERY - EXPLOSIVE GASES! DO NOT SMOKE. KEEP SPARKS AND FLAMES AWAY. VEN- TILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE. ALWAYS WEAR FULL FACE SHIELD AND RUBBER GLOVES WHEN WORKING WITH BATTERIES. • USE EXTREME CAUTION WHEN USING TOOLS, WIRES, OR METAL OBJECTS NEAR BAT- TERIES! A SHORT CIRCUIT AND (OR) SPARK COULD CAUSE AN EXPLOSION.
  • Page 457: 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 458 Battery Care, Continued: 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 459: 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 460: Battery Testing

    NOTE • WHEN A FLEET OF POWERDRIVE SYSTEM 48 VEHICLES IS BEING ROTATED, THE CLUB CAR CDM (COMMUNICATION DISPLAY MODULE) CAN BE A VERY HELPFUL SERVICE TOOL. BY MONITORING THE VALUE OF FUNCTION 3 WITH THE CDM, IT CAN BE DETERMINED WHICH CARS SHOULD BE USED (SEE PAGE 20-22).
  • Page 461 After 5 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...
  • Page 462: Battery Troubleshooting Chart - 36 And 48 Volt

    On-Charge Voltage Test (PowerDrive System 48), Continued: 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 above 9.3 volts and are within 0.7 volts of each other, go to hydrometer test.
  • Page 463 2. Remove the vent cap. 3. Using a battery thermometer (CLUB CAR part No.1011767), record the electrolyte temperature of the No. 2 cell. 4. Squeeze the rubber bulb of the hydrometer and insert into the cell. Slowly release the bulb, drawing electrolyte up into the glass tube of the hydrometer.
  • Page 464 Hydrometer Test, Continued: 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.
  • Page 465 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 V-Glide 36 volt vehicles and PowerDrive System 48 vehicles.
  • Page 466 Performing the Discharge Test, Continued: DANGER • ALWAYS WEAR FULL FACE SHIELD AND GLOVES WHEN WORKING WITH BATTERIES. • BATTERY - EXPLOSIVE GASES! DO NOT SMOKE. KEEP SPARKS AND FLAMES AWAY. VEN- TILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE. USE EXTREME CAUTION WHEN USING TOOLS, WIRES, OR METAL OBJECTS NEAR BATTERIES! A SHORT CIRCUIT AND (OR) SPARK COULD CAUSE AN EXPLOSION.
  • Page 467: Battery Troubleshooting Examples

    V-Glide 36 Volt Vehicle BATTERY VOLTAGES BATTERY CONDITION 5.25 5.25 5.25 5.25 5.25 5.25 EXCELLENT BATTERY NO. 4 IS NEAR END OF USEFUL LIFE BATTERIES NO. 3 AND NO. 5 ARE NEAR END OF USEFUL LIFE PowerDrive System 48 and PowerDrive Plus Vehicles BATTERY VOLTAGES BATTERY CONDITION 7.00...
  • Page 468 Battery Troubleshooting Examples, Continued: PowerDrive System 48 Vehicle BATTERY NO. ON-CHARGE VOLTAGE 10.15 10.60 9.80* 10.16 10.56 10.61 *Battery No. 3 appears to be suspect. Batteries No. 1 and No. 4 are also suspect. Next, a hydrometer test should be conducted on all batteries. Hydrometer test results were as follows: V-Glide 36 Volt Vehicle BATTERY NO.
  • Page 469: Battery Storage

    V-Glide 36 Volt Vehicle BATTERY NO. ON-CHARGE VOLTAGE 7.86 7.33* 7.90 7.93 7.91 7.75 PowerDrive System 48 Vehicle BATTERY NO. ON-CHARGE VOLTAGE 10.48 9.77* 10.53 10.57 10.55 10.33 *Battery No. 2 was immediately suspected as the problem. After checking No. 2 with a hydrometer, this was clearly the case with the negative post cell completely dead.
  • Page 470: Charging Battery Pack With Low Voltage

    PowerDrive System 48 and PowerDrive Plus Vehicle Storage, Continued: 3. Fully charge the batteries prior to storage. 4. Store in a cool area. The colder the area in which the batteries are stored the less the batteries will self- discharge. 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.
  • Page 471 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 WARNING •...
  • Page 472 Page 22-20...
  • Page 473: General Information

    GENERAL INFORMATION Each Club Car V-Glide 36 volt electric vehicle is equipped with a fully automatic Accu-Power battery charger. There are no knobs to turn or buttons to push. The charger will turn on two to five seconds after it is plugged in, and it will automatically shut off when the batteries are fully charged.
  • Page 474 General Information, Continued: CAUTION • DO NOT LEAVE THE DC CORD PLUGGED INTO A VEHICLE RECEPTACLE WHILE UNAT- TENDED FOR MORE THAN TWO DAYS IN A ROW. SEVERE OVERHEATING AND DAMAGE TO THE BATTERIES MAY RESULT IF THE CHARGER DOES NOT TURN OFF. CAPACITOR ELECTRONIC TIMER ASS'Y...
  • Page 475: The Charge Circuit

    THE CHARGE CIRCUIT The charge circuit in the vehicle consists of the charger receptacle, receptacle fuse link, and the batteries. The negative terminal of the receptacle is connected to the No. 6 battery by a 10 gauge white wire, and the positive terminal of the receptacle is connected to the fuse link.
  • Page 476 USE OF IMPROPER EXTENSION CORD COULD RESULT IN FIRE OR AN ELECTRICAL SHOCK. • ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THE CHARGER. CONTACT YOUR NEAREST CLUB CAR DISTRIBUTOR/DEALER. • DO NOT OPERATE THE CHARGER IF IT HAS RECEIVED A SHARP BLOW, WAS DROPPED, OR OTHERWISE DAMAGED IN ANY WAY.
  • Page 477 WARNING • CHARGE BATTERIES ONLY IN A WELL-VENTILATED AREA. • DO NOT LEAVE THE DC CORD PLUGGED INTO A VEHICLE RECEPTACLE WHILE UNAT- TENDED FOR MORE THAN TWO DAYS IN A ROW. SEVERE OVERHEATING AND DAMAGE TO THE BATTERIES MAY RESULT IF THE CHARGER DOES NOT TURN OFF. CONNECT CHARGER ONLY TO A PROPERLY GROUNDED SINGLE PHASE (3 WIRE) OUTLET.
  • Page 478: Troubleshooting

    TROUBLESHOOTING DANGER • HIGH VOLTAGE! WITH THE CHARGER ON, THE VOLTAGE OF THE CAPACITOR INSIDE THE CHARGER IS APPROXIMATELY 650 VOLTS. USE EXTREME CAUTION WHEN WORKING NEAR CAPACITOR TERMINALS. WARNING • ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS CHARGER. ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL REPAIR.
  • Page 479: Test Procedures

    ACCU-POWER BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Charger output is low. One diode failed. Test Procedure 4-A Transformer coil short-circuit failure. Test Procedure 7 Charger turns off too soon. AC power supply was shut off. Test Procedure 3 Batteries may be fully charged.
  • Page 480 Test Procedure 1, Continued: FRONT OF VEHICLE DATA HOLD AC/DC 500V MAX BLACK 250V MAX AC V DC V PROBE PROBE HERE HERE POS. POS. NEG. NEG. NEG. NEG. MEASURE VOLTAGE POS. POS. AT RECEPTACLE FIGURE 23-6 FIGURE 23-7 4. If the voltage readings obtained at the receptacle and at the batteries are not the same, check the wire connections at the receptacle and at the batteries.
  • Page 481 2. If the charger does not turn off automatically when batteries are fully charged, check the connections of the green wire on the heat sink and check the relay (See Test Procedure 9). If the wire connections are secure and the relay has not failed, the Electronic Timer Kit must be replaced. To verify that the timer is malfunctioning: WARNING •...
  • Page 482 Test Procedure 3, Continued: 5. Check continuity of the AC circuit: 5.1. Carefully disconnect the two black wires attached to the contact terminals of the relay. 5.2. Connect a jumper wire between the two black wires. 5.3. With the relay bypassed, check the circuit across the AC cord plug blades (Figure 23-8). 5.4.
  • Page 483 Test Procedure 4A - Single Diode Failure: A single diode failure is indicated by the blowing of one fuse link (short circuited diode) or by low charger out- put (open circuit diode). If a diode has failed, the entire heat sink assembly must be replaced. To check the diodes: 1.
  • Page 484 CAL CORDS, FIRST FROM THE AC OUTLET AND THEN FROM THE VEHICLE RECEPTACLE. 1. Connect the probes of a continuity tester (Club Car Part No. 1011273) to the blades of the charger DC plug and note the reading (Figure 23-11).
  • Page 485 5. If the capacitor is open or shorted, it must be replaced. WARNING • USE A CLUB CAR CAPACITOR (PART NO. 1015910) ONLY. THE USE OF A DIFFERENT VALUE CAPACITOR MAY RESULT IN IMPROPER CHARGING, CAPACITOR FAILURE, TRANSFORMER BURNOUT, AND/OR BATTERY DAMAGE.
  • Page 486 Test Procedure 7 - Transformer, Continued: CAPACITOR ELECTRONIC TIMER ASS'Y BLACK GREEN ORANGE BROWN D.C. CORDSET SECONDARY WHITE OR RED (-) BLACK BLACK BLACK (-) A.C. INPUT PRIMARY PLUG JUMPER GREEN WIRE TO BATTERIES WHITE FUSE A.C. CORDSET AMMETER ASSEMBLY CASE GROUND FIGURE 23-13 Failure of the transformer could be caused by natural aging or premature shorting of adjacent coil turns.
  • Page 487 4. Make sure that the capacitor coil leads and the secondary coil leads are not touching one another. Then, with the relay by-passed, plug the AC cord into an outlet. If the AC line fuse blows or the circuit breaker trips, the transformer is shorted internally and must be replaced. 5.
  • Page 488 2. Disconnect the green wire from the charger case. 3. Connect the alligator clip of a continuity tester (Club Car Part No. 1011273) to the end of the black wire and check for continuity on both flat blades and on the ground blade of AC plug (Figure 23-14). Conti- nuity should be shown on only one flat blade.
  • Page 489 4. Place the probe of the tester on the negative (-) blade of the DC plug. The reading should be no conti- nuity. If the reading is continuity, the cord and plug must be replaced. 5. Attach the alligator clip to the black wire of the DC cord and then place the probe on the negative (-) blade of the DC plug.
  • Page 490: Plug And Receptacle Replacement

    1. Inspect the receptacle for cracks, loose connections and frayed wiring. 2. Insert the tapered end of a test blade (Club Car Part No. 1013930) approximately 1-1/2 inches (38 mm) into one side of the receptacle, then withdraw the blade from the contact, pulling straight out from the receptacle.
  • Page 491 Removing the DC Cord 1. Unplug the AC and DC cords. 2. Remove the charger cover. DANGER • HIGH VOLTAGE! WITH THE CHARGER ON, THE VOLTAGE OF THE CAPACITOR INSIDE THE CHARGER IS APPROXIMATELY 650 VOLTS. USE EXTREME CAUTION WHEN WORKING NEAR CAPACITOR TERMINALS.
  • Page 492 Installing the New DC Cord, Continued: 4. Install the nut (1) on the post of the ammeter and tighten it slightly more than finger tight. While holding the outside of the nut (1), turn the inside nut (2) counterclockwise 1/4 turn (Figure 23-15, Page 23-19). See CAUTION at bottom of page 23-19 and NOTE below.
  • Page 493: On-Board Receptacle Fuse Link

    Receptacle Fuse Link Assembly (Figure 23-16) 1. Install a new fuse link (7) (Club Car Part No. 1012085) into the base (17). 2. Install the nuts (8) which attach the fuse link to the base and tighten them to 15-20 in.lbs. (1.7/2.0 N-m).
  • Page 494: Charger Repairs

    CHARGER REPAIRS WARNING • ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS CHARGER. 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. •...
  • Page 495: Capacitor

    CAPACITOR DANGER • HIGH VOLTAGE! WITH THE CHARGER ON, THE VOLTAGE OF THE CAPACITOR INSIDE THE CHARGER IS APPROXIMATELY 650 VOLTS. USE EXTREME CAUTION WHEN WORKING NEAR CAPACITOR TERMINALS. WARNING • ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS CHARGER. ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL REPAIR.
  • Page 496: Heat Sink Assembly

    Installing the Capacitor, Continued: 3. Connect the terminal connectors to the capacitor terminals. 4. Install the charger cover. 5. Check the charger for proper operation. HEAT SINK ASSEMBLY WARNING • ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS CHARGER. ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL REPAIR.
  • Page 497: Ammeter

    5. Disconnect the capacitor coil leads from the capacitor. See DANGER below. DANGER • HIGH VOLTAGE! WITH THE CHARGER UNPLUGGED AND NOT OPERATING, THE VOLTAGE OF THE CAPACITOR INSIDE THE CHARGER IS STILL APPROXIMATELY 650 VOLTS. USE EXTREME CAUTION WHEN WORKING NEAR CAPACITOR TERMINALS. 6.
  • Page 498: Charger Fuse Link Assembly

    Installing the Ammeter, Continued: FIGURE 23-18 5. Connect the bus bar from the fuse links to the right post of the ammeter. Make sure there is a washer on each side of the bus bar. 6. Install the nuts on both posts of the ammeter and tighten slightly more than finger tight. Then while holding the outside nut, turn the inside nut counterclockwise 1/4 of a turn.
  • Page 499: General Information

    BATTERY CHARGER GENERAL INFORMATION The PowerDrive Battery Charger is an integral part of Club Car’s PowerDrive System 48, and one is included 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. The charger is totally automatic and has no external controls;...
  • Page 500: Battery Warning Light

    This indicates an abnormal charge cycle. The charger and batteries should be checked by your Club Car distributor/dealer. • The warning light will come on during a charge cycle (DC plug is still connected) if AC power to the charger is interrupted.
  • Page 501 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 SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE OR CHARGER.
  • Page 502: Charger Installation And Use

    The Charge Circuit, Continued: WARNING • DO NOT BY-PASS THE SENSE LEAD FUSE! • UNPLUG BOTH THE AC AND DC PLUGS BEFORE WORKING ON THE CHARGER OR CHANG- ING THE CHARGER CORD. • TO CONNECT THE CHARGER PLUG TO THE VEHICLE RECEPTACLE, GRASP THE PLUG AND PUSH IT STRAIGHT INTO THE RECEPTACLE.
  • Page 503 WARNING • IMPROPER CONNECTION OF THE EQUIPMENT-GROUNDING CONDUCTOR CAN RESULT IN RISK OF AN ELECTRICAL SHOCK. • DO NOT USE AN ADAPTER TO PLUG THIS CHARGER INTO A TWO-PRONG OUTLET OR EXTENSION CORD. EXTENSION CORD OR OUTLET MUST ACCEPT GROUNDED THREE- PRONG PLUG.
  • Page 504 Normal Charger Operation, Continued: 2. Connect the charger DC plug to the charger receptacle located on the seat support panel near the driver’s knee (Figure 23-21). The charger will turn on automatically within 2 to 15 seconds after the DC plug is connected.
  • Page 505: Checking Battery Condition After A Charge Cycle

    CHECKING BATTERY CONDITION AFTER A CHARGE CYCLE It is common practice for golf car mechanics to check the condition of a set of batteries after they have charged in order to ensure that they have received a complete charge before the vehicle is used. With the PowerDrive System 48 this is not necessary;...
  • Page 506: Troubleshooting

    TAN WIRE TO PRIMARY COIL PRIMARY COIL SECONDARY COIL GREEN GROUND WIRE BLACK WIRE TO RED WIRE CIRCUIT BREAKER OF D.C. CORD BLACK WIRE TO POWER RELAY BLUE WIRE TO D.C. CORD TAN WIRE TO PRIMARY COIL RED WIRE TO RELAY SECONDARY COIL DC CORD LEADS (TAN)
  • Page 507 CONTINUED FROM PAGE 23-34 DOES CHECK FOR TRIPPED OR CHARGER A.C. FAULTY BREAKER OUTLET HAVE POWER? DETERMINE CAUSE AND RESET BREAKER REPLACE CHARGER THAT MAY BE MALFUNCTIONING WITH ONE THAT IS KNOWN CHARGE BATTERIES TO BE WORKING PROPERLY DOES ORIGINAL CHARGER CHARGER PROBLEM IS IN VEHICLE OPERATE...
  • Page 508 COLUMN ONE COLUMN TWO CONTINUED FROM CONTINUED FROM PREVIOUS PAGE PREVIOUS PAGE DOES CHARGER DETERMINE CAUSE REPLACE RELAY FUSE BLOWN? COME AND REPLACE FUSE CHECK DIODES AS CHARGE BATTERIES CHECK BATTERY VOLTAGE CHARGE BATTERIES DESCRIBED IN TEST PROCEDURE 4, PAGE 23-40 BATTERY INSPECT CHARGER VOLTAGE 36V...
  • Page 509 POWERDRIVE BATTERY CHARGER TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Relay operates intermittently. Blown fuse on red lead from OBC. Section 20 A, Pages 20-3 and 20-4. Defective charger relay. Test Procedure 8 Single charger fuse link blows. Diode failed. Test Procedure 4-A Loose internal fuse connection.
  • Page 510 Test Procedures, Continued: WARNING • ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS CHARGER. 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. •...
  • Page 511: Test Procedures

    PLACE MULTIMETER LEADS HERE EARLY SENSE LEAD FUSE FRONT OF VEHICLE CHARGER RECEPTACLE PLACE VOM LEADS HERE GREY WIRE FROM COMPUTER SENSE LEAD FUSE #6 BLACK FIGURE 23-24 FIGURE 23-25 FIGURE 23-26 5. Plug the original charger (thought to be malfunctioning) into another vehicle that is known to be func- tioning properly.
  • Page 512 Test Procedure 3, Continued: 7. If the circuit is not complete, check the wiring of the AC cord, transformer primary coil leads, internal AC circuit breaker, and jumper wire (Figure 23-31, Page 23-43). 8. If the charger is wired correctly, check the continuity of the AC cord, transformer primary coil, and the jumper wire individually (Test Procedure 8).
  • Page 513 TEST PROCEDURE 5 Continuity Test of Charger DC Circuit: 1. Using the continuity tester (Club Car Part No. 1011273), connect the test leads to the pins marked (+) and (-) on the DC plug (Figure 23-29, Page 23-42), and note the readings.
  • Page 514 Test Procedure 5, Continued: 2. Reverse the test leads and check the DC plug again (Figure 23-30). The circuit should show continuity in only one direction. 3. If the circuit does not show continuity in either direction and the charger fuse is good, individually check the continuity of the DC plug and cord (Test Procedure 8), ammeter (Test Procedure 8), diodes (Test Procedure 4A), and all connections.
  • Page 515 3. Remove the black wire (3) from the circuit breaker and disconnect the tan wire (4) from the relay. Con- nect the tan wire to the circuit breaker (Figure 23-31). 4. Be sure that secondary coil leads are not touching one another. With the relay bypassed, plug the AC plug into an outlet.
  • Page 516 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 23-32). Conti- nuity should be shown on only one flat prong.
  • Page 517 DC Cord and Plug 1. To check the continuity of the DC cord, disconnect the black wire of the DC cord from the ammeter. 2. Disconnect the red wire of the DC cord from the rectifier assembly. 3. Disconnect the blue wire from the relay. 4.
  • Page 518: Plug And Receptacle Replacement

    Relay Continuity Test, Continued: 2. With batteries connected, insert the DC plug into a receptacle. Place continuity leads on contact termi- nals of relay. Tester should show continuity (bulb should light). If tester does not show continuity, the relay must be replaced. Ammeter To check continuity of the ammeter: 1.
  • Page 519: Charger Repairs

    2. Attach the red lead of the new cord set to the terminal and tighten the nut to 12-15 in.lbs.(1.4/1.7 N-m). 3. Attach the blue lead of new cord set to the charger relay (coil) terminal (Figure 23-33). 4. Install nut (1) on post of ammeter slightly more than finger tight. While holding the outside nut (1), turn the inside nut (2) counterclockwise 1/4 of a turn (Figure 23-34).
  • Page 520: Transformer

    TRANSFORMER WARNING • ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS CHARGER. 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. •...
  • Page 521: Fuse Link

    FIGURE 23-35 3. Connect the black wire of the DC cord to the left (when viewed from inside the charger) post of the ammeter. 4. Connect the bus bar from the fuse link to the right post of the ammeter, placing washers on both sides of the bus bar.
  • Page 522: Charger Ac Circuit Breaker

    Charger Relay, Continued: TAN WIRE TO WHITE WIRE PRIMARY COIL FROM AC CORD GREEN GROUND WIRE BLACK WIRE TO CIRCUIT BREAKER BLACK WIRE TO POWER RELAY AC CORD BLUE WIRE TO D.C. CORD RED WIRE TO HEAT SINK AC CIRCUIT TAN WIRE TO BREAKER PRIMARY COIL...
  • Page 523 4. Disconnect the AC cord white wire at the primary coil. 5. Disconnect the AC cord green wire at the charger base. 6. Use a pair of pliers to grip the strain relief bushing and remove it and the AC cord from the charger. Installation of the AC Cord (Figure 23-36) 1.
  • Page 524 Page 23-52...
  • Page 525: General Information

    REVERSE WARNING BUZZER CAN NO LONGER BE HEARD. WHEN THE BUZZER STOPS SOUNDING, THE CONTROLLER IS DISCHARGED. Using a multimeter (Club Car Part No. 1011480) or a continuity tester (Club Car Part No. 1011273), the fol- lowing tests can be performed without disassembling the motor.
  • Page 526 (Figure 24-1). The reading should be continuity. If the reading is incorrect, a possible open field coil or bad connections at terminals maybe the cause. The motor will need to be removed from the vehicle and repaired by a qualified technician (See Motor Removal, Page 24-3). Club Car FIGURE 24-2 FIGURE 24-3...
  • Page 527: Motor Removal

    MOTOR REMOVAL 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. •...
  • Page 528: Motor Disassembly

    Motor Removal, Continued: REMOVE REAR SHACKLE BOLTS TO ALLOW LEAF SPRINGS TO SWING DOWN FIGURE 24-4 8. To gain easier access to the motor, lower the jack, with transaxle, as low as it will go. If more access room is needed, remove the jack from beneath the transaxle and allow the springs to rest on the floor (Figure 24-4).
  • Page 529: Testing And Inspecting Individual Components

    1. Before beginning disassembly, place match marks on the motor end shield and stator shell, and then place the motor in a vice with wooden blocks as shown (Figure 24-5). 2. Using a 5/16” socket, remove the four bolts (8) securing the end shield (10) to the housing with winding assembly (2) (Figure 24-5).
  • Page 530 Visual Inspection of the Armature, Continued: ARMATURE CORE COMMUTATOR FIGURE 24-7 Look for these obvious defects: • Burned, charred or cracked insulation. • Improperly cured varnish. • Thrown solder. • Flared armature windings. • Damaged armature core laminations. • Worn, burned or glazed commutators. •...
  • Page 531 TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 3 PLACES FIGURE 24-8 Page 24-7...
  • Page 532 ARMATURE GROUND TEST CAUTION • DO NOT SUBMERGE THE ARMATURE IN SOLVENT. NOTE • 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 continuity tester or a multimeter set to ohms (Ω), place one probe on the commutator and the other on the armature core.
  • Page 533 THAN 16 OUNCES FIGURE 24-9 FIGURE 24-10 TO REMOVE BEARING USE PRESS AND WEDGE ATTACHMENT TOOL (CLUB CAR PART NO. 1012812) OR SEAL PULLER BEARING PULLER (CLUB CAR PART NO. 1012811) (CLUB CAR #1012809) WHEN USING A PRESS TO REMOVE BEARING FROM...
  • Page 534: Reconditioning The Motor

    (Figure 24-8, Page 24-7). 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 that it will not drop when the bearing is removed (Figure 24-11, Page 24-9).
  • Page 535: Motor Assembly

    TO MAKE A GUIDE RING INSTALLATION TOOL, GLUE A INPUT SHAFT GUIDE RING (CLUB CAR PART NO. 1017891-01) ONTO AN INPUT SHAFT (CLUB CAR PART NO. 1013764) AS GUIDE RING SHOWN AND ALLOW THE GLUE TO SET. (GLUED TO INPUT SHAFT)
  • Page 536 Motor Assembly, Continued: 2. Install the brushes. See NOTE below. NOTE • WHEN INSTALLING NEW BRUSHES, BRUSH SETS CAN BE REMOVED AND REPLACED ONE AT A TIME. THIS METHOD ASSURES THAT THE TERMINALS AND BRUSHES WILL BE PROP- ERLY POSITIONED IN THE RIGGING. •...
  • Page 537: Motor Installation

    WITH BRUSH RIGGING FACING DOWN AND HELD SLIGHTLY ABOVE THE END SHIELD STATOR SHELL AND WINDING ASSEMBLY, MOUNTING SCREW INSERT THE TWO TERMINAL POSTS (THESE SHOULD HAVE BEEN MARKED FOR POSITION) THROUGH THE INSULATORS IN THE STATOR SHELL WALL AT THE A1 AND A2 POSITIONS. INSERT THE RIGGING MOUNTING BOLTS THROUGH THE RUBBER SEALED HOLES IN THE RIGGING AND INTO THE THREADED...
  • Page 538 Figure 22-5 or 22-6, Page 22-5) 12. Reconnect the battery cables, negative (-) first and tighten to 110 in.lb. (12.4 N-m). Coat terminals with Bat- tery Protector Spray (Club Car Part No. 1014305) to minimize corrosion (Figure 22 -5 or 22-6, Page 22-5). VIEWED...
  • Page 539: General Information

    SECTION 25 - REAR SUSPENSION, ELECTRIC VEHICLE GENERAL INFORMATION The rear suspension consists of two leaf springs that are controlled by two shock absorbers mounted between the springs and the vehicle frame. No adjustment or alignment is required. BRAKE CABLE HANGER MOUNTING TYPICAL EACH SIDE OF VEHICLE...
  • Page 540: Shock Absorbers

    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 REPAIR. FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL. • ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE.
  • Page 541 (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. Club Car FIGURE 25-2 FIGURE 25-3 2.
  • Page 542 CAUTION • WHEN INSTALLING THE SPRING PLATE (17), ALIGN THE HOLE IN THE SPRING PLATE WITH THE BOLT HEAD ON THE LEAF SPRING. INSTALL THE U-BOLT (14), TWO LOCK WASHERS (15), AND TWO NUTS (16). TIGHTEN BOTH NUTS (16) FINGER TIGHT, THEN TIGHTEN THEM IN SEVERAL STEPS, ALTERNATING FROM ONE TO THE OTHER, TO 15-20 FT.LBS.
  • Page 544 Golf Cars Club Car Inc. P.O. Box 204658 Augusta, GA 30917-4658...