Multi-Step Potentiometer - Club Car Gasoline Service Manual

MULTI-STEP POTENTIOMETER

20A
E
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
• 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).
• FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED.
• SEE THE SAFETY WARNINGS ON PAGE 20-1.
Testing the Multi-step Potentiometer
See Test Procedure 8, Page 20-17.
Removing the Multi-step Potentiometer
1. Disconnect the batteries (Figure 20-1, Page 20-2) and discharge the controller (See WARNING on
page 20-1).
2. Remove the battery wire connecting batteries No. 5 and No. 6 and the battery wire connecting batteries
No. 5 and No. 4 (Figure 20-1, Page 20-2).
3. Using a 1/2 inch wrench, remove the hold-down brackets from the No. 5 and No. 6 batteries and then
remove the No. 5 and No. 6 batteries from the vehicle (Figure 20-1, Page 20-2).
4. Slide back the ball stud retainer on the potentiometer end of the accelerator rod (1) and disconnect the
accelerator rod from the multi-step potentiometer (Figure 20-20).
5. Disconnect the 18 gauge black (2), white (3), and blue (4) wires from the multi-step potentiometer (Fig-
ure 20-20).
6. Disconnect the 18 gauge green/white wire (5) at the F&R limit switch No. 1 (Figure 20-20).
7. Using a 3/8 inch wrench, remove the nuts (6) and lock washers (7) from underneath the I-Beam and lift
the multi-step potentiometer assembly from the frame. Remove the shim plate (8) (Figure 20-20).
Installing the Multi-step Potentiometer (Figure 20-20)
1. Position the shim plate (8) on the frame I-Beam with the mounting holes properly aligned.
2. Use a flat-blade screwdriver to push the locking tabs out of the retainers, and remove the potentiometer
cover (9).
3. Position the potentiometer on the shim plate and frame with mounting holes aligned and insert the
mounting bolts (10) through the potentiometer base, the shim plate, and the frame as shown.
4. Hold the mounting bolts in place while installing the lock washers (7) and nuts (6). Tighten nuts to
between 18 and 22 in.lbs. (2.0/2.5 N-m).
Page 20-40