General Information - Club Car Gasoline Service Manual

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.
• 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.
• USE EXTREME CAUTION WHEN USING TOOLS, WIRES, OR METAL OBJECTS NEAR BAT-
TERIES! A SHORT CIRCUIT AND (OR) SPARK COULD CAUSE AN EXPLOSION.
• BATTERY - POISON! CONTAINS ACID! CAUSES SEVERE BURNS. AVOID CONTACT WITH
SKIN, EYES, OR CLOTHING. ANTIDOTES:
- EXTERNAL: FLUSH WITH WATER. CALL A PHYSICIAN IMMEDIATELY.
- INTERNAL: DRINK LARGE QUANTITIES OF MILK OR WATER. FOLLOW WITH MILK OF MAG-
NESIA OR VEGETABLE OIL. CALL A PHYSICIAN IMMEDIATELY.
- EYES: FLUSH WITH WATER FOR FIFTEEN MINUTES. CALL PHYSICIAN IMMEDIATELY.
WARNING
• ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING
EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN
GENERAL MECHANICAL AND ELECTRICAL REPAIR. FOLLOW ALL PROCEDURES EXACTLY
AND HEED ALL WARNINGS STATED IN THIS MANUAL.
• ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING
VEHICLE. WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES.
• TURN KEY SWITCH OFF, PLACE FORWARD AND REVERSE ROCKER SWITCH IN THE NEU-
TRAL POSITION, AND REMOVE KEY PRIOR TO SERVICING.
• DO NOT WEAR LOOSE CLOTHING. REMOVE JEWELRY SUCH AS RINGS, WATCHES, CHAINS,
ETC. BEFORE SERVICING VEHICLE.
• ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON-
NECTIONS. WHEN BATTERIES ARE CONNECTED, USE EXTREME CAUTION TO AVOID
SHORTING OF COMPONENTS OR WIRING.
• TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE, DISCONNECT BATTERIES AS
SHOWN IN FIGURE 21-2, PAGE 21-3 WHEN PERFORMING TESTS THAT DO NOT REQUIRE
THE ELECTRICAL SYSTEM TO BE ENERGIZED.

GENERAL INFORMATION

Like the PowerDrive System 48 vehicle, the PowerDrive Plus vehicle features a 48 volt electrical system that
is powered by six eight-volt lead acid batteries, and includes an on-board computer that controls the battery
charger, monitors vehicle usage, and provides test data to the optional Communication Display Module, and
actuates a solenoid lock-out function when the battery charger DC cord is plugged into the receptacle (Fig-
ure 21-1, Page 21-2) (See Section 20 for complete details). The PowerDrive Plus vehicle, however, uses a
"shunt wound" 3.2 hp motor, and includes several additional features:
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