Club Car 1999 DS Manuals

Manuals and User Guides for Club Car 1999 DS. We have 2 Club Car 1999 DS manuals available for free PDF download: Maintenance And Service Manual Supplement, Maintenance Service Manual

Club Car 1999 DS Maintenance And Service Manual Supplement (132 pages)

Club Car PowerDrive Plus Vehicles

Brand: Club Car | Category: Golf Cars | Size: 5.14 MB

Table of Contents
5
Section 10-Periodic Maintenance

9
- General Information
  9
- Daily Pre-Operation Safety Checklist
  10
- Periodic Service Schedule
  11
- Lubrication
  12
- Vehicle Capacities
  12
Section 11-Electrical System and Testing

13
- General Information
  13
- Electrical Circuits
  16
  - The Control Circuit
    16
  - The Power Circuit
    19
  - Electric Motor
    22
  - The Charge Circuit
    22
- Index of Test Procedures
  23
- Diagnostic Flow Charts
  23
- Test Procedures
  26
- The Communication Display Module (CDM)
  34
  - Using the CDM to Retrieve Data from the Onboard Computer
    35
- CDM Troubleshooting Guide
  36
Section 12-Electrical Components

37
- Key Switch
  38
- Forward/Reverse (F&R) Rocker Switch
  39
- Accelerator Pedal Limit Switch
  40
- Reverse Buzzer
  41
- Main Solenoid
  41
- Dynamic Braking Solenoid
  42
- Onboard Computer (OBC)
  43
- Solid State Speed Controller
  45
- Charger Receptacle Assembly
  45
  - Receptacle Fuse Link
    46
- Multi-Step Potentiometer
  47
- Battery Warning Light
  52
- Energy Displacement Module
  54
- Tow/Run Switch
  55
Section 13-Batteries

57
- General Information
  57
- Common Misconceptions about Batteries
  59
- Replacing Batteries
  60
- Battery Care
  61
  - Preventive Maintenance
    61
  - Self-Discharge
    61
  - Electrolyte Level
    61
  - Mineral Content
    62
  - Vibration Damage
    62
- Battery Charging
  62
  - General Information
    62
  - Charger Shuts off after 16 Hours
    63
  - Deep Discharge
    63
  - Early Excessive Discharging
    63
  - Incoming AC Service
    63
  - Fleet Rotation
    63
  - Numbering Vehicles and Chargers
    63
- Battery Testing
  64
  - Battery Charger Test
    64
  - On-Charge Voltage Test
    64
  - Hydrometer Test
    64
  - Battery Troubleshooting Chart
    65
  - Discharge Test
    67
  - Battery Troubleshooting Examples
    69
- Battery Storage
  70
- Charging Battery Pack with Low Voltage
  70
Section 14-Powerdrive Battery Charger

73
- General Information
  73
  - Powerdrive Charging Features
    74
  - Battery Warning Light
    75
- The Charge Circuit
  75
- Charger Installation and Use
  75
- Checking Battery Condition after a Charge Cycle
  79
  - Start Charge Cycle
    79
- Troubleshooting
  80
  - Troubleshooting Guide
    81
- Test Procedures
  84
  - General
    84
- Plug and Cord Replacement
  92
  - Charger Cord and Plug Replacement
    92
- Charger Repairs
  93
  - Heat Sink Assembly
    93
  - Transformer
    94
  - Ammeter
    94
  - Fuse Link
    95
  - Voltage Suppressor
    95
  - Charger Relay
    96
  - Charger AC Circuit Breaker
    97
  - Charger AC Cord
    97
Section 15-Motor

99
- General Information
  99
- External Motor Testing
  100
- Motor
  101
  - Motor Removal
    101
  - Motor Disassembly
    102
- Testing and Inspecting Individual Components
  103
  - Armature
    103
  - Field Windings
    104
  - Motor Components
    106
  - Bearing Inspection
    106
  - Bearing Removal
    106
  - Guide Ring Inspection
    106
- Reconditioning the Motor
  107
- Motor Assembly
  108
- Motor Installation
  110
- Motor Speed Sensor
  110
Section 16-Transaxle

113
- General Information
  114
- Lubrication
  114
- Axle Shaft and Bearing
  114
  - Axle Shaft
    114
  - Axle Bearing
    118
- Transaxle
  120
  - Transaxle Removal
    120
- Transaxle Disassembly, Inspection and Assembly
  122
  - Transaxle Disassembly and Inspection
    122
  - Transaxle Assembly
    124
  - Shimming the Transaxle
    126
- Transaxle Installation
  126

Club Car 1999 DS Maintenance Service Manual (88 pages)

Club Car 1998-1999 DS Golf Cars Gasoline/Electric

Brand: Club Car | Category: Golf Cars | Size: 3.88 MB

Table of Contents
5
Safety

7
- General Warning
  7
Vehicle Specifications

11
- General Information
  11
General Information Section

13
- Model Identiﬁcation
  13
- Safety Committee
  13
- Pre-Operation Checklist
  14
- Controls
  15
- Battery Warning Light
  19
- Driving Instructions
  21
- Towing
  23
- Transporting on a Trailer
  23
- Storage - Gasoline Vehicle
  24
- Storage - Electric Vehicle
  25
Body and Trim

27
- General Information
  28
- Front and Rear Body Repair
  28
- Seat
  30
- Front Body
  30
- Front Body Installation
  31
- Rear Body
  32
- Floormat
  34
Accelerator and Brake Pedal Group

35
Wheel Brake Assemblies

49
Steering and Front Suspension

59
- General Information - Steering
  59
- Steering Wheel
  60
- Steering Column
  60
- Steering Column Assembly
  63
- Steering Adjustment
  64
- Rack and Pinion
  65
- Tie Rod and Drag Link
  68
- Front Suspension
  70
  - Wheel Alignment
    70
  - Camber Adjustment
    70
  - Toe-In Adjustment
    71
  - Tapered Leaf Spring Removal/Installation
    72
  - Kingpin and Steering Spindle Removal
    72
- Front Suspension Components
  72
- Front Wheel Bearings and Hubs
  76
Wheels and Tires

79
- General Information
  79
- Wheel Removal, Repair and Installation
  80
  - Repairing a Tire
    81
  - Installing the Tire on the Rim
    81
Rear Suspension

83
- General Information
  83
- Shock Absorbers
  85
- Leaf Springs
  85

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More Club Car Manuals

Club Car 1999 DS Manuals

Club Car 1999 DS Maintenance And Service Manual Supplement (132 pages)

Table of Contents

Section 10-Periodic Maintenance

Section 11-Electrical System and Testing

Section 12-Electrical Components

Section 13-Batteries

Section 14-Powerdrive Battery Charger

Section 15-Motor

Section 16-Transaxle

Club Car 1999 DS Maintenance Service Manual (88 pages)

Table of Contents

Safety

Vehicle Specifications

General Information Section

Body and Trim

Accelerator and Brake Pedal Group

Wheel Brake Assemblies

Steering and Front Suspension

Wheels and Tires

Rear Suspension

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