Club Car 1995 Golf Car Maintenance Service Supplement Download

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1995 DS ELECTRIC

GOLF CAR WITH

POWERDRIVE SYSTEM 48

MAINTENANCE

S E R V I C E

S U P P L E M E N T

USE WITH 1994

DS GASOLINE/ELECTRIC

MAINTENANCE AND

SERVICE MANUAL

PUBLICATION PART NO.1018293-05

PRINT CODE 0695B0895A

Summary of Contents for 1995 Golf Car

Page 1: ...DS ELECTRIC GOLF CAR WITH POWERDRIVE SYSTEM 48 MAINTENANCE S E R V I C E SUPPLEMENT USE WITH 1994 DS GASOLINE ELECTRIC MAINTENANCE AND SERVICE MANUAL PUBLICATION PART NO 1018293 05 PRINT CODE 0695B08...

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Page 3: ...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 TO AVOID UNINTENTION...

Page 4: ...teries The OBC uses this data also to indicate possible battery or charging problems by illuminating a warning light in the dash For more infor mation on the Battery Trouble Light see Section 19 Page...

Page 5: ...BUZZER HALF SPEED REVERSE 1 8 B L U E 1 8 O R A N G E 1 8 G R E E N 1 8 O R A N G E W H I T E 18 RED WHITE 6 BLUE 6 WHITE 6 Y E L L O W 1 8 R E D 10 BLACK FUSE FUSE 10 BLACK 1 8 W H I T E 1 8 W H I T...

Page 6: ...A N G E 1 8 G R E E N 1 8 B R O W N 18 RED WHITE 6 BLUE 6 W H I T E 6 Y E L L O W 1 8 R E D 1 8 B L U E 1 8 G R E E N 1 8 G R E E N 1 8 G R E E N W H I T E WARNING LIGHT POTENTIOMETER BLUE GREEN WHIT...

Page 7: ...it consists of the multi step potentiometer with discrete resistors With the car in for ward the potentiometer resistance varies from 0 ohms with the accelerator pedal up at rest position to approxima...

Page 8: ...s on intermittently when vehicle is in use and when it is stopped Restore AC power Light will go out and charge will resume Light remains on Glows for 10 seconds Batteries did not receive adequate cha...

Page 9: ...improperly wired Test Procedure 4 Diode 1 failed diode Diode Electrical Components Section 17C Controller Electrical Leakage 1 dirt or acid residue on controller Test Procedure 10 On board Computer 1...

Page 10: ...t of load Test Procedure 10 Tires 1 under inflated or flat tires Inflate or repair tires 4 Vehicle runs full speed in reverse F R Half speed Reverse Limit Switch 3 1 loose or disconnected wires 2 fail...

Page 11: ...the wire to and from the com ponent The probes will often be placed at points removed from the component being tested 17 9 POWERDRIVE TROUBLE SHOOTING GUIDE SYMPTOM PROBLEM POSSIBLE CAUSES REFER TO 6...

Page 12: ...H I T E 18 RED WHITE 6 BLUE 6 WHITE 6 YELLOW 1 8 R E D 10 BLACK 10 BLACK 1 8 W H I T E 1 8 W H I T E 1 8 B L A C K 1 8 B L U E 1 8 B L A C K 1 8 B L A C K 18 WHITE MULTI STEP POTENTIOMETER 1 8 G R E...

Page 13: ...K 10 BLACK 1 8 W H I T E 1 8 W H I T E 1 8 B L A C K 1 8 B L U E 1 8 B L A C K 1 8 B L A C K 18 WHITE MULTI STEP POTENTIOMETER 1 8 G R E E N W H I T E 1 8 G R E E N W H I T E 1 8 B R O W N F U S E WAR...

Page 14: ...with Continuously Variable Potentiometer 1 Place the red probe of the VOM or continuity tester on the large terminal of the solenoid with red wire attached and place the black probe at the green whit...

Page 15: ...ccelerator pedal adjustment See Section 21 5 If the wires are connected correctly and the accelerator pedal is properly adjusted but the readings still not correct replace the switch Vehicle with Cont...

Page 16: ...E 1 8 O R A N G E 1 8 G R E E N 1 8 B R O W N 18 RED WHITE 6 BLUE 6 W H I T E 6 YELLOW 1 8 R E D 1 8 B L U E 1 8 G R E E N 1 8 G R E E N 1 8 G R E E N W H I T E WARNING LIGHT POTENTIOMETER BLUE GREEN...

Page 17: ...RED WHITE 6 BLUE 6 W H I T E 6 YELLOW 1 8 R E D 1 8 B L U E 1 8 G R E E N 1 8 G R E E N 1 8 G R E E N W H I T E WARNING LIGHT POTENTIOMETER BLUE GREEN WHITE WHITE ON BOARD COMPUTER 10 BLACK 10 BLACK 1...

Page 18: ...al Meter should read continuity 2 With the Forward Reverse selector in the forward position place the red probe on the A2 motor ter minal and place the black probe on the S2 motor terminal Meter shoul...

Page 19: ...witch on the Forward Reverse switch Test Procedure 9 Continuously Variable Potentiometer 1 Disconnect the three wire connector connects the potentiometer to the Forward Reverse wire harness from the F...

Page 20: ...CT THE BATTERY CABLES AS SHOWN IN FIGURE 17 1 PAGE 17 2 FAILURE TO DO THIS MAY CAUSE THE VEHICLE TO RUN OVER YOU RESULTING IN SEVERE INJURY OR DEATH WARNING TO AVOID ELECTRICAL SHOCK DISCHARGE THE CON...

Page 21: ...e sure the batteries are connected 4 2 Remove the No 6 white wire from A2 motor terminal and secure it so that it cannot make contact with any live components or connections 4 3 Connect the VOM red pr...

Page 22: ...lem it will be necessary to by pass the OBC solenoid lockout circuit in order to isolate the problem Follow the procedures below 3 1 Make sure that the batteries are disconnected as shown Figure 17 1...

Page 23: ...lf speed reverse limit switch to the end disconnected from terminal with the No 18 black wire from the multi step potentiometer Resistance should measure approximate ly 3900 ohms 10 Continuously Varia...

Page 24: ...er A 1 2 4 or 8 will be displayed 1 Indicates that the last charge cycle was incomplete and that the batteries were not fully charged Batteries should be charged again at the earliest opportunity 2 In...

Page 25: ...he display window release the button The value for F2 will then be displayed 3 To view F3 press and hold the button on the CDM until Func 3 appears in the display window Release the button The value f...

Page 26: ...e Restart OBC by driving car or by connecting charger DC plug CDM LED Dirty or has moisture condensation on it Clean LED Lens On some 1995 PowerDrive System 48 vehicles manufactured between weeks 9526...

Page 27: ...TELY EYES FLUSH WITH WATER FOR 15 MINUTES CALL PHYSICIAN IMMEDIATELY WARNING ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE SOME...

Page 28: ...switch Do not allow wires to touch 6 Remove key switch from the dash by holding the key switch and turning the nut on the outside of the dash with the switch tool CLUB CAR Part No 1012801 or 1 hex so...

Page 29: ...order of disassembly 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...

Page 30: ...he lever arm of each switch is pressed and released per chart above If not correct inspect the F R rotor and limit switches for damage HALF SPEED RESISTOR TO HALF SPEED REVERSE LIMIT SWITCH The half s...

Page 31: ...of a multi meter set to volts to the wire Place the red probe of the multi meter on the positive post of battery No 1 The multi meter should show battery voltage If it doesn t replace the red white wi...

Page 32: ...re If the tester does illuminate replace the buzzer Removing the reverse buzzer 1 Disconnect the batteries Figure 17 1 Page 17 2 and discharge the speed controller See WARNING box on Page 17 25 2 Remo...

Page 33: ...iagram Figure 17 2 or 17 3 THE DIODE SOLENOID A diode is placed across the solenoid activating coil to allow the field to collapse and prevent limit switch fail ures If limit switches are failing the...

Page 34: ...o 10 stud No 18 red wire also attaches to this stud 4 Install and tighten two No 10 nuts to posts Torque to 17 20 in lbs 2 0 2 3 N m RESISTOR SOLENOID A 250 ohms resistor is placed across the contacts...

Page 35: ...Test Procedure 11 Page 17 20 Removing the on board computer 1 Disconnect batteries Figure 17 1 Page 17 2 2 Discharge the controller See instructions in Warning Box on Page 17 25 17 33 WARNING FAILURE...

Page 36: ...emove the OBC from the car Installing the on board computer Install the OBC in reverse order of removal SOLID STATE SPEED CONTROLLER Testing the speed controller See Test Procedure 10 Page 17 18 Remov...

Page 37: ...m the positive post of battery No 1 and then pull the No 10 red wire to the receptacle 2 Figure 17 17 2 Locate the 1 4 quick disconnect terminal on the No 10 grey wire from the charger receptacle Disc...

Page 38: ...e link assembly and lens 6 from the charger receptacle 2 by removing the two nuts 10 and washers also used to secure the No 10 black wire from the computer and the No 10 black wire 5 to the receptacle...

Page 39: ...ash panel inward while pulling the top of the panel out and down 17 37 DANGER TURN KEY SWITCH TO OFF AND REMOVE KEY PUT THE F R SWITCH IN NEUTRAL AND DISCONNECT THE BATTERY CABLES AS SHOWN IN FIGURE 1...

Page 40: ...which is located between the accelerator pedal 5 and the actu ator lever 6 from the pivot rod 7 9 Remove the potentiometer housing cover 8 by removing the two No 4 screws 9 Figure 17 18 10 Remove the...

Page 41: ...that there is approximately an 030 to 090 inch gap between the pawl and the ratchet teeth this can be verified with a feeler gauge 6 Install and tighten nut 10 to between 16 and 20 ft lbs 21 7 27 1 N...

Page 42: ...e Remove the shim plate 8 Figure 17 19 Installing the Multi step Potentiometer Figure 17 19 1 Position the shim plate 8 on the frame I Beam with the mounting holes properly aligned 2 Use a flat blade...

Page 43: ...o 18 black 2 white 3 and blue 4 wires to the multi step potentiometer 6 Connect the accelerator rod 1 to the potentiometer 7 Install and connect the No 5 and No 6 batteries 17 41 Club Car POTENTIOMETE...

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Page 45: ...EAR 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 DO NOT WEAR LOOSE CLOTHING REMOVE JEWE...

Page 46: ...t is generated In a deep cycle battery the negative plates contain lead Pb and the positive plates contain lead dioxide PbO2 These plates are immersed in a sulfuric acid solution H2SO4 Figure 18 1 Dur...

Page 47: ...n used and recharged 20 to 50 times 3 Mineral Content Tap water will do for our batteries It might be OK but have it checked first See Battery Care Page 18 5 4 Self Discharge That dirt and corrosion o...

Page 48: ...SE WARNING BUZZER CAN NO LONGER BE HEARD WHEN THE BUZZER STOPS SOUNDING THE CONTROLLER IS DISCHARGED TO PREVENT ELECTROLYTE LEAKAGE FROM THE BATTERY VENTS BATTERIES MUST BE KEPT IN AN UPRIGHT POSITION...

Page 49: ...es are fully charged and the cells are equalized prior to use BATTERY CARE Preventive Maintenance To keep batteries in good operating condition follow these steps on a regular basis 1 Any corrosion bu...

Page 50: ...er level should be checked weekly to be sure water is at its proper level Figure 18 7 Never allow the water level to fall below the tops of the plates because this will cause the exposed part of the p...

Page 51: ...a full charge Charger Doesn t Shut Off This may be due to one of the following factors 1 New batteries 2 Hard use more than 36 holes per day 3 Cold temperatures 4 Short charging times in late at nigh...

Page 52: ...d to begin with the first test and follow through with the other tests until the problem has been found as outlined in the bat tery troubleshooting chart Figure 18 8 18 8 NOTE WHEN A FLEET OF POWERDRI...

Page 53: ...dings below 7 4V but within 0 5V Old batteries go to hydrometer test Check electrical system and charger for problems See Trouble Shooting Guide Page 19 11 If problem is not found go to on charge volt...

Page 54: ...within 0 5 volts of each other the batteries are old Batteries may have enough capacity left to last several more months Go to hydrometer test See Trouble Shooting Chart Figure 18 8 and examples on fo...

Page 55: ...250 and 1 280 at 80 F Never add acid to batteries to obtain a higher specific grav ity Performing the Hydrometer Test 1 Be sure that the batteries have sufficient water to cover the plates by approxim...

Page 56: ...188 1 270 012 1 258 Bad Center Cell 69 5 80 F 000 1 250 0 1 250 1 255 0 1 255 1 230 0 1 230 Weak Negative Cell Catch up Charge 38 2 100 F 008 1 200 008 1 208 1 180 008 1 188 1 170 008 1 178 Discharge...

Page 57: ...18 10 FIGURE 18 11 DANGER WEAR A FULL FACE SHIELD WHEN WORKING AROUND BATTERIES BECAUSE OF THE DAN GER OF AN EXPLODING BATTERY BATTERY EXPLOSIVE GASES DO NOT SMOKE KEEP SPARKS FLAMES CIGARETTES AWAY T...

Page 58: ...8 vehicles use a VOM to measure individual battery voltages Measure and record the voltage of each battery to the nearest 01 volt 18 14 DANGER WEAR A FULL FACE SHIELD WHEN WORKING AROUND BATTERIES BEC...

Page 59: ...ess than 60 minutes at 78 F on the discharge test will not normally make 36 holes However discharge time is dependent on the electrolyte temperature The table shown gives the discharge times at variou...

Page 60: ...all batteries Hydrometer test results were as follows V Glide 36 volt Vehicle PowerDrive System 48 Vehicle After the hydrometer test it appears that battery No 1 is the problem 18 16 BATTERY NO 1 2 3...

Page 61: ...attery that has the same age and usage as the other batteries BATTERY STORAGE When storing batteries during the off season or maintaining a replacement stock follow these guidelines to keep batteries...

Page 62: ...ery Care Section 2 Batteries should be wired in series so they can be connected to the charger Batteries that are in cars for winter storage can be left in the cars 3 Fully charge the batteries prior...

Page 63: ...cation link between the charger and the on board com puter When the charger plug is plugged into the vehicle s receptacle the on board computer senses its presence and locks out the vehicle s drive sy...

Page 64: ...is restored THE CHARGE CIRCUIT The vehicle charge circuit consists of the charger receptacle fuse link on board computer and the batter ies The negative terminal of the receptacle is connected to the...

Page 65: ...D OR RECEPTACLE HAVE BEEN DAMAGED IN ANY WAY USE OF THE CHARGER WITH ANY OF THESE CONDITIONS COULD RESULT IN A FIRE PROPERTY DAMAGE PERSONAL INJURY OR DEATH DO NOT USE THE CHARGER IF THE DC PLUG DOES...

Page 66: ...arger Keep all charger ventilation openings at least two inches away from walls and other objects 19 4 WARNING EACH CHARGER SHOULD HAVE ITS OWN 15 OR 20 AMPERE BRANCH CIRCUIT PRO TECTION CIRCUIT BREAK...

Page 67: ...l charge rate 19 5 WARNING CONNECT CHARGER ONLY TO A PROPERLY GROUNDED SINGLE PHASE 3 WIRE OUTLET CHARGE BATTERIES ONLY IN A WELL VENTILATED AREA TO CONNECT THE CHARGER PLUG TO THE VEHICLE RECEPTACLE...

Page 68: ...order to ensure that they have received a complete charge before the vehicle is used With the PowerDrive System 48 this is not necessary the vehicle s on board computer controls and monitors the char...

Page 69: ...O RELAY SECONDARY COIL LEADS TAN SECONDARY COIL LEADS BLACK DC CORD BLACK WIRE TO AMMETER DC CORD BLUE WIRE TO RELAY PRIMARY COIL GREEN GROUND WIRE TAN WIRE TO PRIMARY COIL SECONDARY COIL BLACK WIRE T...

Page 70: ...ONE THAT IS KNOWN TO BE WORKING PROPERLY DOES CHARGER OPERATE PROPERLY ORIGINAL CHARGER IS MALFUNCTIONING PROBLEM IS IN VEHICLE CHARGING CIRCUIT LOOK FOR LOOSE CONNECTION OBC MAY BE IN POWER DOWN MODE...

Page 71: ...AY CHECK DIODES AS DESCRIBED IN TEST PROCEDURE 4 PAGE 19 16 DIODES OK REPLACE DIODE RECTIFIER ASSEMBLY CHECK AMP METER AMP METER OK REPLACE AMP METER SEE TROUBLESHOOTING CHART ON PAGE 19 10 YES NO NO...

Page 72: ...EYE PROTECTION WHILE SERVICING VEHICLE OR CHARGER TURN KEY SWITCH OFF AND PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSITION PRIOR TO SERVICING THE CAR TO AVOID UNINTENTIONAL STARTING OF THE CAR...

Page 73: ...e 2 Failed transformer Test Procedure 6 4 Relay operates intermittently Blown fuse on red lead from OBC Section 17 B Electrical Defective charger relay Test Procedure 8 5 Single charger fuse link blow...

Page 74: ...dure 8 Failed transformer Test Procedure 6 11 Battery trouble light remains on with DC charger cord plugged in AC power interrupt Test Procedure 3 On board computer malfunction Test Procedure 2 Charge...

Page 75: ...cted to the positive post of battery No 1 3 2 Make sure that the two nuts that secure the two No 10 AWG black wires to the receptacle fuse assembly are tight 3 3 Check the connections of the No 10 gre...

Page 76: ...ng into another vehicle that is known to be func tioning properly If the charger performs as it should then the charger is not in need of repair TEST PROCEDURE 3 AC POWER AND CONTINUITY CHECK OF AC CI...

Page 77: ...wiring of the AC cord transformer primary coil leads internal AC circuit breaker and jumper wire Figure 19 13 Page 19 19 8 If the charger is wired correctly check the continuity of the AC cord transfo...

Page 78: ...ectifier assembly must be replaced 5 On rare occasions a single fuse link may melt due to excessive heat This can be caused by a loose internal fuse connection Check all three fuse connections inside...

Page 79: ...ster Club Car Part No 1011273 connect the test leads to the pins marked and on the DC plug Figure 19 11 and note the readings 2 Reverse the test leads and check the DC plug again Figure 19 12 The circ...

Page 80: ...it breaker Figure 19 13 Page 19 19 4 Be sure that secondary coil leads are not touching one another With the relay by passed plug the AC plug into an outlet If the AC line fuse or circuit breaker blow...

Page 81: ...CONTINUITY CHECKS AC CORD AND PLUG To check continuity of the AC cord Figure 19 14 Page 19 20 19 19 D C CORDSET RED RED BLUE BLACK BLACK BLACK BLACK BLACK 15 AMP A C CIRCUIT BREAKER A C INPUT PLUG A C...

Page 82: ...laced 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 Disconn...

Page 83: ...y and place the alligator clip on the ammeter buss bar 7 Touch the continuity leads to each secondary coil lead tan You should register continuity bulb should light If you do not register conti nuity...

Page 84: ...ion of the connection 4 Remove the nut that attaches the red lead of the charger DC cord on the rectifier assembly 5 Remove the terminal on the blue charger DC cord lead at the relay 6 Using pliers sq...

Page 85: ...transformer leads tan to the bottom connector of the rectifier assembly Torque nut to 12 15 in lbs 1 4 1 7 N m 4 Connect the other secondary transformer lead tan to the top connector of the rectifier...

Page 86: ...ther secondary transformer lead black to the remaining terminal of the fuse assembly Torque nut to 20 24 in lbs 2 3 2 7 N m 6 Connect the tan primary lead to the charger relay 7 Connect the other prim...

Page 87: ...ad black to the remaining terminal Torque to 24 30 in lbs 2 7 3 4 N m 4 Replace charger cover CHARGER RELAY FIGURE 19 18 PAGE 19 26 Removal of the Charger Relay 1 Unplug the AC and DC cords 2 Remove t...

Page 88: ...the charger through the hole in the charger face 2 Connect the black wire to the circuit breaker the white wire to the primary coil and the green wire to the charger base 3 Position the strain relief...

Page 89: ...F I E L D S E RV I C E B U L L E T I N PEDAL GROUP ADJUSTMENT INSTRUCTIONS ALL CLUB CAR VEHICLES New Pedal Group Incorporation Effective 2 6 95 Bulletin No 95 5 Revised Club Car R...

Page 90: ...S IN THIS AND ALL OTHER APPLICABLE PUBLI CATIONS ALWAYS WEAR APPROVED EYE PROTECTION WHEN SERVICING THE VEHICLE BEFORE BEGINNING WORK ON THE VEHICLE PARK IT ON A FIRM AND LEVEL SURFACE TURN THE KEY SW...

Page 91: ...the following ways 1 On all vehicles the accelerator pedal extension spring has been replaced by a compression spring 2 On all vehicles the pivot rod supports are now injection molded with replaceabl...

Page 92: ...e pawl See Figure 2 Detail B 6 4 Then with the park brake still locked measure the distance from the top of the accelerator pedal to the floorboard again If the measurement has changed ratchet tooth e...

Page 93: ...accelerator pedal with accelerator pedal height toward floorboard position pedal at 5 5 8 plus or minus 1 8 as shown in Figure 3 Tighten nut to 12 15 ft lbs 8 Page 5 2 1 ACTUATOR LEVER FLOORBOARD ACCE...

Page 94: ...ctuator lever counter clockwise to exactly the point where the microswitch breaks the circuit multimeter reads open circuit 8 6 Without moving the actuator lever tighten the bolt Item 5 attaching actu...

Page 95: ...Page 7 3 4 5 POTENTIOMETER HOUSING ASSEMBLY FIGURE 4 2 6 1 4 3 POTENTIOMETER HOUSING ASSEMBLY SIDE VIEW OF POTENTIOMETER HOUSING ASSEMBLY WITH COVER CUT AWAY...

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