Club Car 1998 Maintenance And Service Manual Supplement
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Club Car 1998 Maintenance And Service Manual Supplement

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1998-1999
Maintenance and
Service Manual
Supplement
PowerDrive Plus Vehicles
Manual Number 101968405
Edition Code 0299C1208B

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Summary of Contents for Club Car 1998

  • Page 1 1998-1999 Maintenance and Service Manual Supplement PowerDrive Plus Vehicles Manual Number 101968405 Edition Code 0299C1208B...
  • Page 3 PowerDrive Plus electric vehicle. If you need additional information, you may write to us at: Club Car, Inc.; P.O. Box 204658; Augusta, GA 30917 or contact a Club Car technical ser- vice representative at (706) 863-3000, ext. 3580.
  • Page 4 SPECIFICATIONS OR MODIFICATIONS WHICH AFFECT THE STABILITY OF THE VEHICLE OR THE OPERATION THEREOF, WILL VOID THE WARRANTY. • CLUB CAR, INC. RESERVES THE RIGHT TO CHANGE SPECIFICATIONS AND DESIGNS AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION OR LIABILITY WHATSOEVER.

  • Page 5: Table Of Contents

    12-13 Multi-step Potentiometer Arm Brush Replacement ..................12-14 Multi-step Potentiometer Adjustment ......................12-15 Resistors ................................ 12-15 Battery Warning Light ........................12-16 Energy Displacement Module ......................12-18 Tow/Run Switch ..........................12-19 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page iii...
  • Page 6 Start Charge Cycle ............................14-7 Troubleshooting ..........................14-8 Troubleshooting Guide ..........................14-9 Test Procedures ..........................14-12 General ................................. 14-12 Plug and Cord Replacement ......................14-20 Charger Cord and Plug Replacement ......................14-20 Page iv 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement...
  • Page 7 Transaxle Removal ............................16-8 Transaxle Disassembly, Inspection and Assembly ................16-10 Transaxle Disassembly and Inspection ......................16-10 Transaxle Assembly ............................16-12 Shimming the Transaxle ..........................16-14 Transaxle Installation ........................16-14 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page v...
  • Page 8 Page vi 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement...

  • Page 9: Section 10-Periodic Maintenance

    These checks can easily be performed when moving the vehicle from the storage facility to the starting line. Any vehicle that is not functioning properly should be removed from service until it has been repaired. 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 10-1...

  • Page 10: Daily Pre-Operation Safety Checklist

    DAILY PRE-OPERATION SAFETY CHECKLIST Inspect and drive the vehicle. Use the Pre-operation Checklist and Performance Inspection in Section 3–General Information located in the 1998/1999 DS Maintenance and Service Manual as a guide to check the following items. • Vehicle warning decals •...

  • Page 11: Periodic Service Schedule

    Periodic Service Schedule PERIODIC SERVICE SCHEDULE WARNING • SERVICE, REPAIRS, AND ADJUSTMENTS MUST BE MADE PER INSTRUCTIONS IN THE 1998/1999 DS GOLF CAR MAINTENANCE & SERVICE MANUAL AND THIS SUPPLEMENT. NOTE • IF THE VEHICLE IS CONSTANTLY SUBJECTED TO HEAVY USE OR SEVERE OPERATING CONDITIONS, THE PREVENTATIVE MAINTENANCE PROCEDURE SHOULD BE PERFORMED MORE OFTEN THAN RECOMMENDED IN THE SERVICE AND LUBRICATION SCHEDULES.

  • Page 12: Lubrication

    SERVICE PLACE RECOMMENDED LUBRICANT Brake pedal shaft bearings Dry Moly Lube - Club Car Part No. 1012151 Brake Linkage and Pivots Dry Moly Lube - Club Car Part No. 1012151 Semi-Annually by Owner or Accelerator push rod pivots and mounts Dry Moly Lube - Club Car Part No.

  • Page 13: Section 11-Electrical System And Testing

    There are three features of the PowerDrive Plus electrical system which will activate the motor braking function: Zero Speed Detect, Pedal Down Motor Braking, and Pedal Up Motor Braking. 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 11-1...
  • Page 14 ELECTRICAL SYSTEM AND TESTING General Information Figure 11-1 Wiring Schematic - Place Holder for Fold-out Drawing Page 11-2 1998/1999 PowerDrive Plus Maintenance and Service Supplement...
  • Page 15 (PIN 9) PURPLE WIRE (PIN 14) LT GRN WIRE (PIN 10) ORANGE WIRE (PIN 13) GREEN WIRE (PIN 11) BLUE/WHITE WIRE (PIN 12) BROWN WIRE MOTOR Figure 11-2 Wiring Diagram 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 11-3...

  • Page 16: Electrical Circuits

    The Control Circuit consists of three individual circuits, 1) Onboard Computer Circuit (Figure 11-4, Page 11-6), 2) Solid State Speed Control Circuit (Figure 11-5, Page 11-8), and 3) Tow Switch Circuit (Figure 11-6, Page 11- Page 11-4 1998/1999 PowerDrive Plus Maintenance and Service Supplement...
  • Page 17 Pin 9 provides a constant 5-volt signal to the multi-step potentiometer. Pin 16 completes the negative circuit for the motor speed sensor through the black wire. (PIN 16) BLACK WIRE Figure 11-3 23-Pin Connector Plug 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 11-5...
  • Page 18 7. Sends a signal from the dash light to the optional Communication Display Module. SONIC WELD CONTROLLER SIX-PIN CONNECTOR (PIN 1) RED WIRE (PIN 2) ORN/WHT WIRE (PIN 6) YELLOW WIRE RESISTOR 14 15 (PIN 13) GREEN WIRE Figure 11-4 Onboard Computer Circuit Page 11-6 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 19: The Power Circuit

    The Power Circuit consists of: • Battery Pack (six eight-volt batteries) • Solid State Speed Controller • Electric Motor • Solenoid Contacts • Energy Displacement Module (Resistor Coil) • All 6 Gauge Power Wires 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 11-7...
  • Page 20 (PIN 14) LIGHT GREEN WIRE (PIN 12) BROWN WIRE (PIN 11) BLUE/WHITE WIRE (PIN 10) ORANGE WIRE (PIN 9) PURPLE WIRE MOTOR (PIN 16) BLACK WIRE Figure 11-5 Solid State Speed Control Circuit Page 11-8 1998/1999 PowerDrive Plus Maintenance and Service Supplement...
  • Page 21 ELECTRICAL SYSTEM AND TESTING Electrical Circuits SONIC WELD SONIC WELD CONTROLLER SIX-PIN CONNECTOR (PIN 3) GRN/WHT WIRE 14 15 Figure 11-6 Tow Switch Circuit/Components CONTROLLER MOTOR Figure 11-7 Power Circuit 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 11-9...

  • Page 22: Electric Motor

    DC cord is plugged into the vehicle’s charger receptacle. The batteries will be discussed in Section 13–Batter- ies. CONTROLLER Figure 11-8 Charge Circuit FRONT OF VEHICLE PLACE TOW SWITCH IN THE TOW POSITION BEFORE REMOVE NEGATIVE DISCONNECTING BATTERY CABLE FIRST CABLES Figure 11-9 PowerDrive Plus Battery Configuration Page 11-10 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 23: Index Of Test Procedures

    DIAGNOSTIC FLOW CHARTS The diagnostic flow charts included in this section may be used as a reference when performing test procedures on the PowerDrive Plus vehicle. More detailed system testing instructions follow. 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 11-11...
  • Page 24 TERMINAL POSTS TEST PROCEDURE 5 REPLACE REPLACE CONTROLLER MOTOR LOW VOLTAGE READING CHECK FOR SHORT CIRCUIT IN MOTOR SHORT CIRCUIT REPLACE MOTOR Figure 11-10 Flow Chart 1 - Vehicle Does Not Operate Page 11-12 1998/1999 PowerDrive Plus Maintenance and Service Supplement...
  • Page 25 VOLTAGE NOT ABOVE 3.5 VDC REPAIR OR REPLACE TEST PROCEDURE 10 AS REQUIRED REPLACE MOTOR SPEED SENSOR REPLACE SPEED CONTROLLER Figure 11-12 Flow Chart 3 - Vehicle Operates, No Motor Braking 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 11-13...

  • Page 26: Test Procedures

    If reading is zero volts, check blue wire terminal connectors inside six-pin connec- tor at OBC six-pin connector. Make sure pins are properly aligned inside housing. Make sure wire colors match. Page 11-14 1998/1999 PowerDrive Plus Maintenance and Service Supplement...
  • Page 27 The reading should be approximately 3.75 volts with the pedal up. Slowly depress the accelerator pedal and note the readings on the multimeter. As the pedal is depressed, the reading will decrease in increments until it reaches zero volts when the pedal is fully depressed. 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 11-15...
  • Page 28 4. If the reading is zero volts with switch in the RUN position, check continuity of the two-pin connector and the red/ white 18 gauge wire from the large post of the solenoid to the two-pin connector at the Tow/Run switch. Page 11-16 1998/1999 PowerDrive Plus Maintenance and Service Supplement...
  • Page 29 1. Before proceeding with this test procedure, the batteries must be fully charged. Using a 36 to 48-volt battery discharge machine (Club Car No. 101831901), connect the positive (+) lead of the discharge machine to bat- tery No. 1 positive post and connect the negative (-) lead to battery No. 6 negative post. Record reading from discharge machine.
  • Page 30 Test Procedure 11 - Onboard Computer Silicon Controlled Rectifier (SCR) Circuit 1. A silicon controlled rectifier (SCR) acts as a switch between the two black wires in the OBC to complete the negative Page 11-18 1998/1999 PowerDrive Plus Maintenance and Service Supplement...
  • Page 31 6 negative post and place red lead on red/green wire terminal socket in three-pin connector. Voltage reading should be from 5.01 to 5.08 volts. 3.2. If the voltage reading is zero volts, check the continuity of the red/green wire from the 23-pin connector 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 11-19...
  • Page 32 2. Place the black lead on the blue wire terminal 1 position on the rocker switch and place the red lead on the red/white wire terminal. With the switch in REVERSE, there should be continuity. If the readings are incorrect, replace the switch. Page 11-20 1998/1999 PowerDrive Plus Maintenance and Service Supplement...
  • Page 33 (that was disconnected from the reverse buzzer) and place the red lead on battery No. 1 positive post. The reading should be approximately 48 volts (full battery voltage). 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 11-21...

  • Page 34: The Communication Display Module (Cdm)

    A problem may exist if persistent DVDT readings are obtained. Page 11-22 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 35: Using The Cdm To Retrieve Data From The Onboard Computer

    • To view F3, press and hold the button on the CDM until “Func 3” appears in the display window. Release the button. The value for F3 will be displayed. 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 11-23...

  • Page 36: Cdm Troubleshooting Guide

    CDM TROUBLESHOOTING GUIDE Use the following chart as a starting point for troubleshooting problems with communication between the CDM and onboard computer. Contact your Club Car representative for more comprehensive information. OBC Does Not Communicate With CDM Defective Dash Light...

  • Page 37: Section 12-Electrical Components

    • IF WIRES ARE REMOVED OR REPLACED MAKE SURE WIRING AND/OR WIRING HARNESS IS PROPERLY ROUTED AND SECURED TO VEHICLE FRAME. FAILURE TO PROPERLY ROUTE AND SECURE WIRING COULD RESULT IN VEHICLE MALFUNCTION, PROPERTY DAMAGE OR PERSONAL INJURY. 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 12-1...

  • Page 38: Key Switch

    6. From the back of the dash panel, push down on the retaining tabs surrounding the key switch (4) and remove the key switch cap (8). Hold the key switch and remove the switch retaining nut (6) from the outside of the dash panel (Figure 12-2, Page 12-3). Page 12-2 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 39: Forward/Reverse (F&R) Rocker Switch

    2. Connect red/white (4), blue (5), and white (6) 18 gauge wires to rocker switch (Figure 12-3, Page 12-4). 3. Install the three self tapping screws (3) that hold the F&R rocker switch case (2) to the body (Figure 12-3, Page 12-4). Tighten to 20 in.lb (2.2 N-m). 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 12-3...

  • Page 40: Accelerator Pedal Limit Switch

    6. Connect battery cables to battery No. 1 positive (+) first, then connect cable to battery No. 6 negative (–). Tighten ter- minals to 110 in.lb (12.4 N-m). 7. Place Tow/Run switch in RUN. Page 12-4 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 41: Reverse Buzzer

    The main solenoid is located on the passenger side of the electrical component mounting plate. Testing the Main Solenoid See Test Procedure 3, Section 11, Page 11-15. TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 12-4 Main Solenoid 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 12-5...

  • Page 42: Dynamic Braking Solenoid

    Figure 12-5 Dynamic Braking Solenoid DYNAMIC BRAKING SOLENOID Read DANGER and WARNING on page 12-1. The dynamic braking solenoid is located on the driver side of the electrical component mounting plate. Page 12-6 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 43: Onboard Computer (Obc)

    Slide OBC towards inside of vehicle and align heads of self tapping screws (17) with smaller part of two holes in OBC face plate (Figure 12-6, Page 12-8). Tighten screws to 60 in.lb (6.7 N-m). 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 12-7...
  • Page 44 10. Reconnect battery cables (positive cable first) and tighten to 110 in.lb (12.4 N-m) (Figure 12-1, Page 12-2). Place Tow/Run switch in RUN. TYPICAL 2 PLACES TYPICAL 3 PLACES Figure 12-7 Speed Controller Page 12-8 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 45: Solid State Speed Controller

    1. Insert the 10 gauge red wire (4) and the 18 gauge gray wire (3) through the hole in the vehicle body and the receptacle backing plate (Figure 12-8, Page 12-10). 2. Insert receptacle into vehicle body. 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 12-9...

  • Page 46: Receptacle Fuse Link

    2. Place the two 10 gauge black wires in their original positions on the fuse link mounting posts. 3. Install nuts (2) on fuse link mounting posts and tighten to 19 in.lb (2.1 N-m) (Figure 12-8, Page 12-10). Page 12-10 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 47: Multi-Step Potentiometer

    (33) was removed, insert it through the bell crank with ball stud facing down and away from housing and install the nut (35). While holding ball stud with a wrench, tighten the nut to 5 ft.lb (7 N-m) (Figure 12-13, Page 12-17). 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 12-11...
  • Page 48 (10) through the potentiometer base, the shim plate, and the frame as shown (Figure 12-9, Page 12-12). 4. Hold the mounting bolts in place while installing the washers (7) and nuts (6). Tighten nuts to 36 in.lb (4.1 N- m) (Figure 12-9, Page 12-12). Page 12-12 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 49: Multi-Step Potentiometer Arm Adjustment

    BURNED, THE ENTIRE HOUSING, WITH FIXED CONTACTS, MUST BE REPLACED. • A THREAD LOCKING COMPOUND HAS BEEN PLACED ON THE THREADS OF THE CONTACT STUDS TO PREVENT REMOVAL OF THE FIXED CONTACTS. 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 12-13...

  • Page 50: Multi-Step Potentiometer Arm Brush Replacement

    12. Check wiper arm brush contact for proper adjustment. See Page 12-13. 13. Check accelerator and brake pedal adjustment. See Section 5–Accelerator and Brake Pedal Group in the Maintenance and Service Manual. Page 12-14 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 51: Multi-Step Potentiometer Adjustment

    (Figure 12-12, Page 12-16). 4. Install the 1000 ohm resistor assembly (29) (color bands brown, black, red, and gold) onto the sixth and sev- enth threaded posts (Figure 12-12, Page 12-16). 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 12-15...

  • Page 52: Battery Warning Light

    8. Install seven 1/4-20 hex nuts onto the threaded posts (with resistors attached) and tighten to 40 in.lb (4.5 N- m) (Figure 12-12, Page 12-16). 9. Coat all terminals with Battery Protector Spray (Club Car Part Number 1014305) to minimize corrosion. BATTERY WARNING LIGHT Read DANGER and WARNING on page 12-1.
  • Page 53 ELECTRICAL COMPONENTS Battery Warning Light TYPICAL 7 PLACES REFERENCE ACCELERATOR TYPICAL 2 PLACES Figure 12-13 Multi-step Potentiometer 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 12-17...

  • Page 54: Energy Displacement Module

    2. Reconnect battery cables (positive cable first) and tighten to 110 in.lb (12.4 N-m). Place the Tow/Run switch in the RUN position. DYNAMIC BRAKING RESISTOR COILS SOLENOID Figure 12-14 Energy Displacement Module Page 12-18 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 55: Tow/Run Switch

    2. Reconnect battery wires, positive cable first, and tighten to 110 in.lb (12.4 N-m). Coat terminals with Battery Protector Spray (Club Car Part No. 1014305) to minimize corrosion. 3. Place Tow/Run switch in the RUN position. 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 12-19...

  • Page 57: Section 13-Batteries

    10-25 amperes in stop and go driving. The energy removed from an automotive battery is immediately replaced by the alternator or generator. As a result, the automotive battery oper- ates at 90 to 100% of full charge at all times. 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 13-1...
  • Page 58 The separator is porous enough to allow charged ions to pass through between the positive and nega- tive plates, but not allow the two materials to contact each other. Whenever two unlike metals are immersed in an acid solution, an electric current is generated. Page 13-2 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 59: Common Misconceptions About Batteries

    Misconception- “You should tighten battery hold-downs as tight as you can”. Reality- Battery hold-downs should be tightened to specification. Hold-downs that are too tight or too loose can cause battery damage. See Battery Care,Page 13-5. 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 13-3...

  • Page 60: Replacing Batteries

    Tighten to 40 in.lb (4.5 N-m), alternating between hold-down bolts. Page 13-4 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 61: Battery Care

    Any frayed or worn wires should be replaced. After all cables have been connected, coat all terminals with Battery Protector Spray (CLUB CAR Part No.1014305) to help prevent future corrosion. 2. Batteries should be kept clean and dry to prevent self-discharge. Any dirt, grime or acid spillage should be removed.

  • Page 62: Mineral Content

    The charger supplied with the PowerDrive Plus electric vehicle resolves the most common problems associated with battery charging. Undercharging and overcharging are prevented provided the charger is allowed to shut off Page 13-6 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 63: Charger Shuts Off After 16 Hours

    NOTE • WHEN VEHICLES ARE BEING ROTATED, THE CLUB CAR CDM (COMMUNICATION DISPLAY MODULE) CAN BE A VERY HELPFUL SERVICE TOOL. MONITORING THE VALUE OF FUNCTION 3 WITH THE CDM SIMPLIFIES VEHICLE USAGE SCHEDULING. SEE SECTION 11, PAGE 13-22.

  • Page 64: Battery Testing

    1. Be sure batteries have sufficient electrolyte to cover plates by approximately 1/2 in. and are fully charged prior to beginning test. If water must be added, recharge the batteries before performing the hydrometer test. 2. Remove the vent cap. Using a battery thermometer (CLUB CAR part No.1011767), record the electrolyte tem- perature of the No. 2 cell.

  • Page 65: Battery Troubleshooting Chart

    Replace battery. Go to Section 14–PowerDrive useful life. Replace set. end of discharge. Replace battery. Go to Section 14–PowerDrive useful life. Replace set. Battery Charger. Battery Charger. Figure 13-7 Troubleshooting Chart 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 13-9...
  • Page 66 If the difference between the cells is .020 or more, the low cell should be suspected. It may require a catch-up charge or it may be a weak cell. When the variations between cells reach .050 or more, the battery with the low cell should be replaced. Page 13-10 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 67: Discharge Test

    5. When the batteries have been discharging for approximately 60 minutes, set the discharge machine to function 3 and check battery set voltage. Check voltage every 10 minutes throughout the rest of the test. As soon as the battery 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 13-11...
  • Page 68 54 Minutes 110 - 119 70 Minutes 70 - 74 57 Minutes 120 - 129 72 Minutes 75 - 79 60 Minutes 130 - 150 74 Minutes 80 - 84 62 Minutes Page 13-12 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 69: Battery Troubleshooting Examples

    *Battery No. 2 was immediately suspected as the problem. After checking battery No. 2 with a hydrometer, it was discovered that the negative post cell was completely dead. Battery No. 2 should be replaced with a battery that has the same age and usage as the other batteries. 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 13-13...

  • Page 70: Battery Storage

    2. If battery pack voltage is below 34 volts, the charger will not activate. The charger relay will have to be by- passed in order for the charger to activate. 3. Disconnect the DC cord from the charger receptacle and unplug the AC cord from the electrical outlet. Page 13-14 1998/1999 PowerDrive Plus Maintenance and Service Supplement...
  • Page 71 14. When the charge cycle is complete, test the batteries again. If the battery pack voltage is above 34 volts and the vehicle will not operate, it will be necessary to troubleshoot the vehicle’s electrical system to determine which electrical component has failed. See Section 11–Electrical System and Testing. 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 13-15...

  • Page 73: Section 14-Powerdrive Battery Charger

    The charger then shuts off automatically, preventing the possibility of either undercharging or overcharging. The computer accomplishes this by detecting when the exact amount of energy required has been returned to the batteries. 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14-1...

  • Page 74: Powerdrive Charging Features

    This will help prevent possible damage to the plug and receptacle due to arcing. Page 14-2 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 75: Battery Warning Light

    • TO CONNECT THE CHARGER PLUG TO THE VEHICLE RECEPTACLE, GRASP THE PLUG AND PUSH IT STRAIGHT INTO THE RECEPTACLE. DO NOT ROCK OR BEND THE PLUG. WARNING CONTINUED ON FOLLOWING PAGE... 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14-3...
  • Page 76 SHOCK. • DO NOT USE AN ADAPTER TO PLUG CHARGER INTO A TWO-BLADE OUTLET OR EXTENSION CORD. EXTENSION CORD OR OUTLET MUST ACCEPT GROUNDED THREE-BLADE PLUG. WARNING CONTINUED ON FOLLOWING PAGE... Page 14-4 1998/1999 PowerDrive Plus Maintenance and Service Supplement...
  • Page 77 2. Connect charger DC plug to charger receptacle located on the seat support panel (Figure 14-3, Page 14-6). The charger will activate automatically within 2 to 15 seconds after the DC plug is connected. 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14-5...
  • Page 78 Always monitor the first charge cycle to make sure the charger turns off properly. If the DC cord is disconnected dur- ing a charge, and the batteries are less than 90% charged, the battery warning light will illuminate intermittently. See Battery Warning Light, Page 14-3. Page 14-6 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 79: Checking Battery Condition After A Charge Cycle

    15 AMP AC CIRCUIT BREAKER SECONDARY RELAY COIL BLACK BLACK FUSE AMMETER ASS'Y PRIMARY COIL AC INPUT PLUG CASE GREEN GROUND AC CORDSET WHITE Figure 14-4 PowerDrive Battery Charger Wiring Diagram 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14-7...

  • Page 80: Troubleshooting

    The Troubleshooting Guide on pages 14-9 and 14-10 encompasses the entire vehicle electrical system.The flow charts on pages 14-10 through 14-12 refers specifically to the onboard computer and battery charger. Test proce- dures specified in these charts can be found on the pages immediately following. Page 14-8 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 81: Troubleshooting Guide

    Charger turns off too soon. AC power supply was shut off. Test Procedure 3, Page 14-14 Onboard computer malfunction. Test Procedure 2, Page 14-13 Batteries may be fully charged. Test Procedure 7, Page 14-17 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14-9...
  • Page 82 Test Procedure 2, Page 14-13 Battery or batteries need to be replaced. Section 13–Batteries OBC/CHARGER WILL NOT CHARGE BATTERIES CHECK POWER TO CHARGER OUTLET CONTINUED ON NEXT PAGE Figure 14-6 Flow Chart Page 14-10 1998/1999 PowerDrive Plus Maintenance and Service Supplement...
  • Page 83 TEST PROCEDURE 6, PAGE 14-16 CHARGE BATTERIES CHECK OBC FUSE IN RED WIRE COLUMN ONE CONTINUED ON NEXT PAGE COLUMN TWO CONTINUED ON NEXT PAGE Figure 14-7 Flow Chart, Continued 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14-11...

  • Page 84: Test Procedures

    2. Inspect the receptacle contacts to ensure that they are not damaged and they are firmly seated within the receptacle. 3. Check the wire connections to the charger receptacle: Page 14-12 1998/1999 PowerDrive Plus Maintenance and Service Supplement...
  • Page 85 FRONT OF VEHICLE CHARGER RECEPTACLE PLACE MULTIMETER GRAY WIRE BLACK (-) LEAD HERE FROM COMPUTER SENSE LEAD FUSE NO. 6 BLACK Figure 14-9 Receptacle Wire Connections Figure 14-10 Battery Pack 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14-13...
  • Page 86 3. Using a low voltage continuity tester or multimeter set to diode test function, connect the red (+) tester lead to the diode mounting plate and the black (-) tester lead to a diode terminal and note the reading (Figure 14- Page 14-14 1998/1999 PowerDrive Plus Maintenance and Service Supplement...
  • Page 87 20 in.lb (2.2 N-m). 5. Be sure the charger is wired properly and all connections are clean and tight. DISCONNECT SECONDARY COIL LEAD Figure 14-12 Diode Test Figure 14-13 Diode Test–Reverse Probe Position 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14-15...
  • Page 88 Test Procedure 5 - Charger DC Circuit Continuity Test 1. Using a continuity tester (Club Car Part No. 1011273) or multimeter set to 200 ohms, connect the test leads to the pins marked (+) and (-) on the DC plug (Figure 14-14, Page 14-16) and note the readings.
  • Page 89 2. Disconnect black wire (1) of AC cord from charger AC circuit breaker (3) (Figure 14-17, Page 14-18). 3. Disconnect green wire (2) from charger case and position it so it does not touch any metal part of the charger (Figure 14-17, Page 14-18). 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14-17...
  • Page 90 10. Place the continuity tester probe on the negative (-) pin of the DC plug. Tester should register continuity. If tester does not register continuity, cord and plug must be replaced. Page 14-18 1998/1999 PowerDrive Plus Maintenance and Service Supplement...
  • Page 91 3. Place continuity leads on contact terminals of relay. With batteries connected, insert the DC plug into the receptacle. Tester should register continuity. If tester does not register continuity, the relay must be replaced. 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14-19...

  • Page 92: Plug And Cord Replacement

    (Figure 14-19, Page 14-20). 4. Remove nut attaching red lead of charger DC cord onto the heat sink assembly (Figure 14-18, Page 14-20). Page 14-20 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 93: Charger Repairs

    3. Connect one of the secondary transformer leads (tan) to the bottom terminal post of the heat sink assembly. Tighten nut to 18 in.lb (2.0 N-m) (Figures 14-4 and 14-5, Pages 14-7 and 14-8). 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14-21...

  • Page 94: Transformer

    5. Thread nuts onto both posts of the ammeter until just past finger tight. While holding the outside nut, turn the inside nut counterclockwise 1/4 turn (Figure 14-20, Page 14-23). See following CAUTION. Page 14-22 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 95: Fuse Link

    See also Test Procedure 8–Continuity, Voltage Suppressor, Page 14-19. 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14-23...

  • Page 96: Charger Relay

    BLACK WIRE TO CIRCUIT BREAKER AC CORD BLUE WIRE TO DC CORD VOLTAGE SUPPRESSOR (RED WIRE) TO AC CIRCUIT HEAT SINK BREAKER TAN WIRE TO PRIMARY COIL CHARGER RELAY Figure 14-21 Charger Relay Page 14-24 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 97: Charger Ac Circuit Breaker

    3. Position the strain relief bushing on the AC cord. 4. Using pliers, install the strain relief bushing and AC cord into the mounting hole in the charger face. 5. Install the charger cover. 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 14-25...

  • Page 99: Section 15-Motor

    The PowerDrive Plus vehicle is equipped with a 48-volt DC, shunt wound, reversible traction motor. The shunt wound motor is designed for use on the PowerDrive Plus vehicle only. Club Car recommends motors requiring major repair be sent to a qualified motor repair shop. However, there are many relatively simple tasks that can be performed by a technician with general knowledge and experience in electric motor repair.

  • Page 100: External Motor Testing

    An incorrect reading for the F1 or F2 terminal indicates a possible grounded F1 or F2 terminal or field coil. Figure 15-1 Test for Motor Short Circuit Page 15-2 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 101: Motor

    1000 LBS. (454 KG.) MINIMUM LIFTING CAPACITY. DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION. ALWAYS USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE. 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 15-3...

  • Page 102: Motor Disassembly

    8. To remove brush springs (14) from the rigging, lift the spring extensions out and over the brush mounts and then slide the springs off their mounting tabs (Figure 15-6, Page 15-5). Page 15-4 1998/1999 PowerDrive Plus Maintenance and Service Supplement...

  • Page 103: Testing And Inspecting Individual Components

    A dirty or oily commutator should be cleaned and wiped dry. Abnormalities identified during the inspection can help determine original cause of failure. Slight roughness of the commutator can be polished smooth with 400 grit or finer sandpaper. See following CAUTION and NOTE. 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 15-5...

  • Page 104: Field Windings

    Burned or scorched insulation on the field windings indicates the motor has overheated due to overloads or grounded or shorted coil windings. If the insulation on the field windings is scorched, replace the motor or the sta- tor shell assembly. Page 15-6 1998/1999 PowerDrive Plus Maintenance and Service Supplement...
  • Page 105 MOTOR Testing and Inspecting Individual Components TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 3 PLACES Figure 15-8 Motor 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 15-7...

  • Page 106: Motor Components

    (Figures 15-8 and 15-12, Pages 15-7 and 15-11). Make sure the wedge attachment tool is supporting the inner race of the bearing. If a press is not available, secure a bearing puller (Club Car Part No. 1012811) to the bearing and pull the bearing off of the end of the armature shaft. Support the shaft so it will not drop when the bearing is removed (Figure 15-12, Page 15-11).

  • Page 107: Reconditioning The Motor

    Guide Ring Installation 1. Coat the outside surface of the new guide ring with a thin film of guide ring adhesive (Club Car Part No. 101813201), then slide the guide ring onto the guide ring installation tool (Figure 15-11, Page 15-9) next to the guide ring already in place.

  • Page 108: Motor Assembly

    Release the brushes and place the springs outside the brushes so the brushes are being held against the commutator. See following CAUTION. 6. Install end shield onto the stator shell. Page 15-10 1998/1999 PowerDrive Plus Maintenance and Service Supplement...
  • Page 109 8, Page 15-7). Tighten the screws to 90 in.lb (10 N-m). NOTE • MAKE SURE THE MOTOR SPEED SENSOR LEAD LOCATED ON THE END SHIELD IS ALIGNED WITH THE F2 AND A2 TERMINALS ON THE MOTOR HOUSING. 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 15-11...

  • Page 110: Motor Installation

    11. Connect the battery cables (positive cable first). Tighten cables to 110 in.lb (12.4 N-m) (Figure 15-1, Page 15- 2). Coat terminals with Batter Protector Spray (Club Car Part No. 1014305) to minimize corrosion. Place Tow switch in the RUN position.
  • Page 111 Figure 15-14 Brush Installation Figure 15-15 End Shield Installation VIEWED FROM DRIVER SIDE INSTALL MOTOR ON TRANSAXLE, ALIGN AND INSTALL MOUNTING BOLT Figure 15-16 Motor Installation Figure 15-17 Motor Mount 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 15-13...
  • Page 112 3. Reconnect the three-pin connector (22) (Figure 15-18, Page 15-14). 4. Reconnect battery cables (positive cable first) and tighten to 110 in.lb (12.4 N-m). Coat terminals with Batter Protector Spray (Club Car Part No. 1014305) to minimize corrosion. Place Tow/Run switch in the RUN position (Figure 15-1, Page 15-2).

  • Page 113: Section 16-Transaxle

    - TURN KEY SWITCH ON, PLACE FORWARD/REVERSE ROCKER SWITCH IN REVERSE. - SLOWLY DEPRESS THE ACCELERATOR PEDAL AND KEEP IT DEPRESSED UNTIL THE REVERSE WARNING BUZZER CAN NO LONGER BE HEARD. WHEN THE BUZZER STOPS SOUNDING, THE CONTROLLER IS DISCHARGED. 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 16-1...

  • Page 114: General Information

    5. Use a 16 in. (40 cm) rolling wedge bar (Figure 16-2, Page 16-3) to remove oil seal. Insert the wedge bar underneath the seal lip and pry out oil seal (Figure 16-3, Page 16-3) . See following CAUTION. Page 16-2 1998/1999 PowerDrive Plus Maintenance and Service Supplement...
  • Page 115 7. Inspect bearing (5) (Figure 16-4, Page 16-4 or Figure 16-5, Page 16-5). If the bearing in a Type K transaxle is worn or damaged, replace bearing. If the bearing in a Type G transaxle is worn or damaged, see following NOTE at Axle Bearing. Figure 16-3 Seal Lip 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 16-3...
  • Page 116 TRANSAXLE Axle Shaft and Bearing REFERENCE MOTOR— SECTION 15 TYPICAL 2 PLACES Figure 16-4 Transaxle - Type K Page 16-4 1998/1999 PowerDrive Plus Maintenance and Service Supplement...
  • Page 117 TRANSAXLE Axle Shaft and Bearing REFERENCE MOTOR— SECTION 15 Figure 16-5 Transaxle - Type G 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 16-5...

  • Page 118: Axle Bearing

    Axle Bearing Removal (Type K Transaxle Only) 1. Remove the retaining ring (7) from the axle shaft (Figure 16-4, Page 16-4). 2. Place a bearing puller wedge attachment (Club Car Part No. 1012812) on the axle shaft between the wheel mounting flange and the bearing.
  • Page 119 2. Place new seal (17) (Figure 16-4, Page 16-4) or (15) (Figure 16-5, Page 16-5) in axle tube with seal lip facing away from the bearing. Use an axle seal tool (Club Car Part No. 1014162) and mallet to tap it in until it seats firmly in position (Figure 16-7, Page 16-6).

  • Page 120: Transaxle

    Figure 16-8 Support Vehicle on Jackstands Figure 16-9 Disconnect Brakes REMOVE BOLTS, THEN ROTATE SHACKLES UP AND AWAY FROM SPRING DISCONNECT SHOCK ABSORBERS FROM LOWER MOUNTS Figure 16-10 Disconnect Shocks Figure 16-11 Shackles Page 16-8 1998/1999 PowerDrive Plus Maintenance and Service Supplement...
  • Page 121 13. Carefully lift each end of the transaxle off its positioning pin (on the leaf spring) and slide the transaxle to the rear and out of the vehicle. 14. If removal of the brake assemblies is required, see Section 6–Wheel Brake Assemblies in the 1998/1999 DS Vehicle Maintenance and Service Manual.

  • Page 122: Transaxle Disassembly, Inspection And Assembly

    Page 16-5) from the input pinion gear. If the oil seal (10) is damaged, replace it (Figures 16-4 or 16-5, Pages 16-4 or 16-5). See also Figure 16-15, Page 16-10. CAUTION • DO NOT REUSE BEARINGS AFTER REMOVING THEM. REPLACE BEARINGS WITH NEW ONES. Page 16-10 1998/1999 PowerDrive Plus Maintenance and Service Supplement...
  • Page 123 16-4 or 16-5, Pages 16-4 or 16-5). See also Figure 16-19, Page 16-11. SIDE THRUST GEAR WASHER DIFFERENTIAL LEFT PUSH DIFFERENTIAL DIFFERENTIAL GEAR PIN THROUGH CASE DIFFERENTIAL GEAR CASE Figure 16-19 Differential Pin Figure 16-20 Left Differential 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 16-11...

  • Page 124: Transaxle Assembly

    5. Apply grease to the lip of the new oil seal (10) (Figures 16-4 or 16-5, Pages 16-4 or 16-5) and install the seal using a transaxle pinion seal tool (Club Car Part No. 1014161). The lip of the oil seal should face the inside of the transaxle housing.
  • Page 125 22 ounces of SAE 30 API Class SE, SF, or SG oil (a higher grade may also be used). Install and tighten the level indicator plug to 23 ft.lb (31 N-m). 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 16-13...

  • Page 126: Shimming The Transaxle

    (14) on the differential case assembly (32) (Figure 16-4, Page 16-4) See also Figure 16-21, Page 16-14. 3. Use the following chart to determine whether shimming is required and, if so, how many shims (Club Car Part No. 1013781) should be used.
  • Page 127 11. Lift the vehicle and remove the jackstands. 12. Lower vehicle and tighten the lug nuts (using a criss-cross pattern) to 55 ft.lb (74.6 N-m). 13. Test drive the vehicle to check for proper operation. 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 16-15...
  • Page 129 Club Car NOTES...
  • Page 130 Club Car NOTES...
  • Page 132 Club Car, Inc. www.clubcar.com P.O. Box 204658 Phone 1.706.863.3000 Augusta, GA 30917-4658 1.800.ClubCar Int’l +1 706.863.3000 1.706.863.5808...

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1999Powerdrive plus 1999

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