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Club Car 1996 DS Golf Car Gasoline, Service Manual

The Club Car 1996 DS Golf Car Gasoline is a reliable and durable vehicle perfect for your golfing adventures. Ensure proper maintenance and repairs with the free Service Manual available for download from manualshive.com. This manual will guide you through any necessary fixes to keep your golf car running smoothly.

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DS GOLF CARS

GASOLINE/ELECTRIC

MANUAL NUMBER 101905101

EDITION CODE 1196H0799C

MAINTENANCE

S E R V I C E

1995-1996

Summary of Contents for 1996 DS Golf Car Gasoline

Page 1: ...DS GOLF CARS GASOLINE ELECTRIC MANUAL NUMBER 101905101 EDITION CODE 1196H0799C MAINTENANCE S E RV I C E 1995 1996...

Page 2: ......

Page 3: ...lub Car s continuing commitment to customer support This service manual covers all aspects of DS Golf Car service However unique situations do sometimes arise when servicing a golf car If it appears t...

Page 4: ...ctric Vehicle 3 12 PERIODIC MAINTENANCE SECTION Lubrication Gasoline Vehicles 4 2 Lubrication Electric Vehicles 4 3 Vehicle Capacities 4 4 Periodic Service Gasoline Vehicles 4 5 Periodic Service Elect...

Page 5: ...neral Information 6 1 Pedal Group Adjustment Early 1995 Vehicles 6 1 Pedal Group Disassembly and Assembly Early 1995 Vehicles 6 9 Pedal Group Adjustment Late 1995 and 1996 Vehicles 6 13 Pedal Group Di...

Page 6: ...TION Lubrication 9 1 Axle Shaft 9 2 Axle Bearing 9 3 Removing the Transaxle 9 5 Disassembly Inspection and Assembly of the Transaxle 9 10 Shimming the Transaxle 9 14 Installation of the Transaxle 9 15...

Page 7: ...building the Cylinder Head 13 7 Rebuilding Crankcase Components 13 23 Engine Assembly 13 46 Service Specifications 13 47 Specifications for Resizing Cylinder Bore 13 49 Torque Specifications 13 49 Adj...

Page 8: ...oting 19 5 Circuit Testing 19 8 ELECTRICAL COMPONENTS V GLIDE 36 VOLT VEHICLE SECTION Key Switch 19 18 Forward and Reverse Anti arcing Limit Switch 19 19 Accelerator Pedal Limit Switch 19 20 The Rever...

Page 9: ...Guide 21 20 Test Procedures 21 25 Numerical Listing of Test Procedures 21 25 ELECTRICAL COMPONENTS POWERDRIVE PLUS SECTION Key Switch 21 53 Forward and Reverse Switch 21 54 Reverse Buzzer 21 54 Main...

Page 10: ...on 23 27 Battery Warning Light 23 28 The Charge Circuit 23 28 Charger Installation and Use 23 30 Checking Battery Condition after a Charge Cycle 23 33 Troubleshooting 23 34 Test Procedures 23 37 Plug...

Page 11: ...HAZARD WHICH COULD RESULT IN SEVERE PER SONAL INJURY A CAUTION INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN MINOR PERSONAL INJURY OR DAMAGE TO THE VEHICLE OR OTHER PROPERTY A NOTE PROV...

Page 12: ...UST SYSTEMS FAILURE TO HEED THIS WARNING COULD RESULT IN SEVERE BURNS LIFT ONLY ONE END OF A VEHICLE AT A TIME BEFORE LIFTING LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITAB...

Page 13: ...n helical gear with 12 28 1 direct drive axle Electrical System 12 volt 460 cold cranking amp battery and 35 amp charging capacity Electrical System 48 volts DC reduced speed reverse Electrical System...

Page 14: ...2 98 cm 38 1 2 98 cm 38 1 2 98 cm Weight Standard electric vehicle without batteries 455 lbs 206 kg 455 lbs 206 kg 448 lbs 203 kg Weight Fairway Villager electric vehicle without batteries 495 lbs 225...

Page 15: ...FOUR PASSENGER VEHICLE READ THE SPECIAL INSTRUCTIONS IN THE DS OWNER S MANUAL FIGURE 3 1 FIGURE 3 2 SIGNS SUCH AS STEEP HILL AND SHARP TURN ARE AVAILABLE FROM THE GOLF CAR MAN UFACTURERS ASSOCIATION M...

Page 16: ...is at its proper level See Fig ure 22 7 Section 22 Page 6 Check battery posts Wires should be tight and free of corrosion Charge batteries fully before first use of vehicle DS V Glide Speed Switch Be...

Page 17: ...lumn See Figure 3 3 Page 3 4 It has two positions OFF and ON which are clearly labeled DO NOT OPERATE THE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION GASOLINE ENGINES PRODUCE CARBO...

Page 18: ...tion or push down the R reverse side of the switch to run the vehicle in reverse When the switch is positioned with neither side down the vehicle is in the NEUTRAL position and the vehicle will not ru...

Page 19: ...forward with your foot See Figure 3 8 GASOLINE VEHICLES ONLY NEUTRAL LOCK OUT The vehicle has a neutral lock out circuit that prevents the driver from starting the vehicle in NEUTRAL If the vehicle is...

Page 20: ...ng on If the oil warning light goes on and off you may proceed but oil should be added at the first opportunity If the oil level is correct and the light stays on have a trained mechanic check the veh...

Page 21: ...ain illuminated for 10 seconds if the charge is less than 90 complete but the car has enough power to complete 36 holes of golf This will alert the fleet operator that the car may be used but that it...

Page 22: ...UNSUSPECTING PASSENGER AND OR DAMAGE TO THE VEHICLE A BUZZER WILL SOUND AS A WARNING WHEN THE VEHICLE IS IN REVERSE WHEN DRIVING THE VEHICLE OPERATE THE VEHICLE FROM THE DRIVER S SEAT ONLY TO PREVENT...

Page 23: ...key switch ON the zero speed detect function will resist vehicle rolling See Zero Speed Detect Page 3 3 TOWING All vehicles are equipped with both front and rear tow bar attaching points A light duty...

Page 24: ...F MORE THAN ONE VEHICLE MUST BE TOWED A PROPERLY FITTED VEHICLE WITH A TOW HITCH HEIGHT OF 11 INCHES 28 CM SHOULD BE USED ONLY HEAVY DUTY TOW BARS SHOULD BE USED FOR MULTI VEHICLE TOWING NEVER TOW MOR...

Page 25: ...on See Periodic Lubrication Sched ule Section 4 Page 4 2 6 Thoroughly clean front body rear body seats engine compartment and underside of vehicle 7 Do not latch the park brake Block tires to prevent...

Page 26: ...rear body seats battery compartment and underside of vehicle 7 Do not latch the park brake Block tires to prevent the vehicle from rolling 8 Keep batteries fully charged during storage See Section 22...

Page 27: ...Section 22 Page 7 2 Readjust tire pressure to 18 20 psi 3 Perform the Pre Operation Checklist See Pages 3 2 and 3 3 A POWERDRIVE SYSTEM 48 VEHICLE WILL NOT OPERATE WHILE PLUGGED TO A CHARGER POWERDRI...

Page 28: ...Page 3 14 3 E G...

Page 29: ...IR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL TURN KEY SWITCH OFF PLACE FORWARD AND REVERSE SWITCH IN THE NEUTRAL POSI TION AND REMOVE KEY PRIOR TO SERVICING MOVING PART...

Page 30: ...Only Every 200 rounds or 100 hours of operation Check fill transaxle to plug level 5 22 oz 67 liter SAE 30 WT API Class SE SF or SG Oil or higher Inspect front wheel bearings Repack as necessary 6 Ch...

Page 31: ...Car Part No 1012151 Accelerator pivots 3 Dry Moly Lube Club Car Part No 1012151 Forward and reverse switch contacts and charger receptacle 4 WD 40 Front Suspension 5 fittings 5 Chassis Lube EP NLGI 2...

Page 32: ...7 liters 22 oz 67 liters Gasoline Tank 7 gallons 26 5 liters Tire Pressure 12 14 psi 83 96 kPa 18 20 psi 124 138 kPa IF ANY PROBLEMS ARE FOUND DURING SCHEDULED INSPECTION OR SERVICE DO NOT OPERATE THE...

Page 33: ...essary Engine cooling air intake Check for clogging clean as necessary Fuel System Check fuel tank lines cap pump and carburetor for fuel leakage Park Brake Check for proper operation See Section 3 Pa...

Page 34: ...Section 6 Accelerator governor linkage and cables Check for proper operation adjust as necessary See Section 14 Steering Lubricate per Gas Vehicle Lubrication Chart on Page 4 2 General Vehicle Lubrica...

Page 35: ...ack wheel bearings with chassis lube as neces sary See Section 8 Page 8 25 Starter Generator Check brush length remove excess carbon dust replace as necessary See Section 12 Transaxle Check fill trans...

Page 36: ...19 24 kph Check all daily items listed above Monthly Service by Owner or Trained Mechanic Batteries Wash battery tops with baking soda water solution Brake System Check for proper operation See Perfo...

Page 37: ...ekly monthly and quarterly items listed above Annual Service by Trained Mechanic Only Every 200 rounds or 100 hours of operation Accelerator Switch Wiper Switch or Continuously Variable Potentiometer...

Page 38: ...Page 4 10 4 E G...

Page 39: ...EY BEFORE SERVICING THE VEHICLE 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...

Page 40: ...that do not penetrate the clear coat can be buffed out using most commercially available automotive polishing compounds and polishes LARGE SCRATCHES AND ABRASIONS To repair large scratches that penet...

Page 41: ...the proper contour Figure 5 5 Page 5 4 If needed apply additional resin and hardener mixture to fill in any low spots or pinholes Figure 5 6 Page 5 4 Allow twenty four hours for the epoxy to cure tho...

Page 42: ...ed surface and coat with light even strokes Figure 5 8 Addi tional coats may be required 9 Apply any commercially available clear coat Follow the manufacturer s instructions SEAT Proper cleaning of th...

Page 43: ...REPAIRING BODY PANELS TURN KEY SWITCH OFF PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI TION AND REMOVE KEY BEFORE SERVICING THE VEHICLE DO NOT WEAR LOOSE CLOTHING REMOVE JEWELRY SUCH AS RINGS...

Page 44: ...Forward and Reverse Switch to the rear body then pull the Forward and Reverse Switch from the rear body and place it on the vehicle frame I beam with wiring intact Disconnect the three wires from the...

Page 45: ...e seat back support assembly to the rear body Figure 5 14 8 Lift the seat back assembly from the vehicle Retain seat back assembly mounting pads Item 4 Fig ure 5 13 9 Lift the rear body from the vehic...

Page 46: ...ation 2 Remove the protective backing paper from the insulation s adhesive surface 3 Position the insulation on the rear body and press firmly to adhere it 4 Install the rear body as instructed above...

Page 47: ...ND OF A VEHICLE AT A TIME BEFORE LIFTING LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LBS 454 KG MINIMUM LI...

Page 48: ...L STOP ADJUSTMENT SEE PAGE 6 6 THROUGH PAGE 6 8 PARK BRAKE ADJUSTMENT SEE PAGE 6 8 IF ANY OF THE ITEMS ABOVE REQUIRE ADJUSTMENT THE OTHER ITEMS MUST ALSO BE CHECKED AND ADJUSTED IF NECESSARY IN THE OR...

Page 49: ...box cover The electrical component box is located under the seat next to the battery Retain the cover and the screw for later installation 3 2 Disconnect the accelerator rod 10 at the accelerator ped...

Page 50: ...nts occur as described in step 3 4 3 7 Install the electrical component box cover and screw AFTER ACCELERATOR ROD ADJUSTMENT MAKE SURE THAT APPROXIMATELY THE SAME NUMBER OF THREADS IS EXPOSED AT EACH...

Page 51: ...RIVE SYSTEM 48 VEHICLES AS INSTRUCTED IN WARNING ON PAGE 6 1 THIS WILL PREVENT THE POSSIBILITY OF THE VEHICLE RUNNING OVER YOU WHEN YOU ARE ADJUSTING THE ACCELERATOR ROD FOR V GLIDE VEHICLES SEE FIGUR...

Page 52: ...ust the ball joint sleeve so that it will fit onto the wiper switch ball stud with approximately the same number of threads show ing at each end of the rod Then tighten the jam nut against the sleeve...

Page 53: ...the wiper switch is activated There should be at least 1 2 1 27 cm of travel measured from the top of the accelerator pedal at rest position to the point where the limit switch is activated An audibl...

Page 54: ...sure the brake pedal and cable are adjusted as instructed in steps 1 and 2 Pages 6 2 and 6 3 5 3 Disconnect the push rod 10 from the accelerator pedal 1 Figure 6 5 Page 6 3 See DAN GER below FIGURE 6...

Page 55: ...tchet and pawl If the gap is not between 030 and 125 0 8 to 3 2 mm Figure 6 11 See Adjust the Accelerator Pedal Stop Page 6 7 5 3 Lock the park brake With the park brake locked make sure that at least...

Page 56: ...Figure 6 13 Tighten the nut 24 on the equalizer rod so that brake pedal free play is 1 4 inch to 1 2 inch 6 35 mm to 12 7 mm Figure 6 4 Page 6 2 See NOTE at top of next page FIGURE 6 13 EACH HALF OF E...

Page 57: ...ark brake rod 9 into the park brake pawl Figure 6 15 2 Install the push nut 11 onto the park brake pawl shaft Figure 6 15 3 Install the spacer 21 and torsion spring 20 on the park brake pedal shaft on...

Page 58: ...Pedal Assembly Early 1995 Electric Vehicles 1 Remove the accelerator rod by sliding back the ball joint sleeve and disconnecting the ball joint 11 from the ball joint stud 6 Figure 6 7 Page 6 5 2 Remo...

Page 59: ...the bolts and nuts to 70 80 in lbs 8 9 N m Figure 6 7 Page 6 5 4 Place the plastic spacer 22 on the accelerator pivot rod Push the pivot rod into the spacer until the end of the rod is even with the e...

Page 60: ...VEHICLE ALWAYS BEFORE SERVICING DISCONNECT BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG FRAME GROUND DO NOT ALLOW WRENCH OR OTHER METAL OBJECTS TO CONTACT FRAME WHE...

Page 61: ...AND POWERDRIVE PLUS VEHICLES THE ACTUATOR LEVER MUST ALSO BE ADJUSTED IF THE RATCHET PAWL GAP IS ADJUSTED SEE STEP 4 PAGE 6 19 ON DS V GLIDE 36 VOLT ELECTRIC AND ON DS GASOLINE POWERED VEHICLES THE A...

Page 62: ...al to the pivot plate Clamp the accelerator pedal adjustment tool Club Car Part No 1018710 01 to the accelerator pedal with the end marked accelerator pedal height toward the floorboard then depress t...

Page 63: ...ND PLACE THE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSITION TO PREVENT ACCIDENTAL STARTING OF THE ENGINE DISCONNECT THE BATTERY CABLES NEGATIVE FIRST THIS WILL PREVENT THE POSSIBILITY OF THE VEHICL...

Page 64: ...nnect the acceler ator rod from the wiper switch ball stud Then try to reconnect it If the accelerator pedal must be released in order to reconnect the accelerator rod then the wiper switch arm is exe...

Page 65: ...uator Lever There is no accelerator rod on PowerDrive vehicles 4 1 Connect the Calibration Test Module Club Car Part No 1018871 01 Figure 6 28 Page 6 20 to the vehicle 4 1 1 Disconnect the 3 wire conn...

Page 66: ...30 03 VOLT SIGNAL BY PRESSING TEST BUTTON CONNECT TEST SOCKET TO POT PLUG CONNECT GREEN LEAD TO GREEN WHITE POT LIMIT SWITCH LEAD CONNECT BLUE LEAD TO BATTERY POSITIVE ILLUMINATION OF THE L E D INDICA...

Page 67: ...3 42 volts Then tighten the potentiometer lock nut to 4 6 in lbs 45 68 N m See Figure 6 34 4 9 Again loosen the actuator lever bolt and rotate the actuator lever counterclockwise until the red LED goe...

Page 68: ...dard PowerDrive System 48 vehicles or to the wiring har ness on PowerDrive Plus vehicles 4 13 Check potentiometer adjustment See Section 20A Page 20 17 4 14 Install the potentiometer housing cover THE...

Page 69: ...y switch is off and that the Forward and Reverse Switch is in neutral then disconnect the battery or batteries as shown Figure 12 1 Page 12 2 for gasoline vehicles or Figure 22 5 or 22 6 Page 22 5 for...

Page 70: ...ar wheels and lift the front end of the vehicle with a chain hoist or floor jack Place jackstands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands See WARNING...

Page 71: ...nd spacer 22 from the accelera tor pivot rod supports 23 Figure 6 27 Page 6 19 See NOTE below 12 Pull accelerator pedal 1 out of vehicle from the top side of the floorboard Figure 6 27 Page 6 19 INSTA...

Page 72: ...chet onto the splines of the pivot rod it may be necessary to push the pivot rod toward the driver side of the vehicle to make the splines accessible The ratchet may have to be rotated counterclockwis...

Page 73: ...nect the spring retainer 12 from the accelerator pivot rod assembly 6 Figure 6 35 Page 6 22 9 Remove the crescent retaining ring 16 from the accelerator pivot rod Figure 6 35 Page 6 22 10 Depress the...

Page 74: ...e end of the pivot rod is flush with the outside surface of the pivot rod support 22 Figure 6 35 Page 6 22 4 Rotate the potentiometer lever 27 clockwise until lever fork is at the two o clock position...

Page 75: ...to widen the gap or counterclockwise to reduce the gap Figure 6 35 Page 6 22 If the gap is 125 or more slide the ratchet off the splines rotate the ratchet clockwise one spline and then slide the ratc...

Page 76: ...Page 6 30 6 E G...

Page 77: ...RE SERVICING VEHICLE MOVING PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING LIFT ONLY ONE END OF A VEHICLE AT A TIME BEFORE LIFTING LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON...

Page 78: ...Page 7 2 7 E G FIGURE 7 1 yyy yyy yyy yy yy 1 10 11 8 8 6 15 9 4 3 2 5 14 13 12 7 7 6 TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 4 PLACES 16 SELF ADJUSTING WHEEL BRAKE ASSEMBLY...

Page 79: ...MS ARE HANDLED WEAR APPROVED EYE AND RESPIRATORY PROTECTION WHEN DISASSEMBLING AND CLEANING BRAKE MECHANISMS INHALATION OF ASBESTOS COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH DO NOT USE COMPRESSE...

Page 80: ...SHAFT CLEAN ANY RESIDUAL OIL FROM THE EXPOSED END OF THE AXLE SHAFT AND FROM THE OIL SEAL AREA FIGURE 7 4 FIGURE 7 5 SOME BRAKE SHOES CONTAIN ASBESTOS FIBER AND ASBESTOS DUST IS CREATED WHEN THESE BR...

Page 81: ...ttom of page 7 4 FIGURE 7 6 FIGURE 7 7 FIGURE 7 8 FIGURE 7 9 FIGURE 7 10 FIGURE 7 11 1 2 3 LUBRICATE SLIDE 1 AND SLIDE PLATE 2 WITH DRY GRAPHITE LUBRICANT THEN WORK THE SLIDE BACK AND FORTH 1 2 USE A...

Page 82: ...ASSENGER SIDE OF THE VEHICLE THE SIDE OF THE TRAILING SHOE FLANGE MARKED 17T SHOULD BE FACING OUT AND BE VISIBLE ON THE DRIVER SIDE THE 17L ON THE LEADING SHOE SHOULD BE FACING OUT AND BE VISIBLE WHEN...

Page 83: ...While holding the arm up turn the wheel upward until it stops Figure 7 16 Remove the screwdriver 7 Install the axle shaft into the axle tube and install the retaining ring Figure 7 3 Page 7 3 8 Insta...

Page 84: ...TING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LBS 454 KG MINIMUM LIFTING CAPACITY DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION ALWAYS USE APPROVED JACKSTANDS OF PROPER WEIG...

Page 85: ...AIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LBS 454 KG MINIMUM LIFTING CAPACITY DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION ALWAYS USE...

Page 86: ...sure to align the match marks placed on the wheel and steering column in Step 2 of Steering Wheel Removal 2 Install the washer and steering wheel nut Tighten the nut to 12 14 ft lbs 16 3 19 N m minimu...

Page 87: ...d mount 4 and 5 from the steering column Figure 8 2 Page 8 4 2 While supporting the steering shaft 19 on a workbench remove the snap ring 13 from the shaft 3 Remove the washer 14 spring 15 and wedge 1...

Page 88: ...m lip of the bearing seat 18 and remove the bearing 17 Figure 8 2 DO NOT DAMAGE THE BEARING OR BEARING SEAT WHILE REMOVING THE BEARING FIGURE 8 2 CAUTION y y y y y y yy yy yy yy 34 33 28 32 31 26 27 2...

Page 89: ...tool Club Car Part No 1014259 to seat the retaining ring to the proper depth If you do not have the recommended tool use the same tube as was used in Step 2 to press the retaining ring onto the top of...

Page 90: ...8 8 to adjust the length of the drag link rod so that with the rack at its limit of travel in a right hand turn the passenger side spin dle just touches the passenger side A plate The internal stop o...

Page 91: ...CAPACITY TO SUPPORT THE VEHICLE GASOLINE VEHICLES ONLY TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE ALWAYS BEFORE SERVICING DISCONNECT BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE F...

Page 92: ...g a ball joint removal tool remove the ball joint 13 Figure 8 7 from the spindle assembly See Figures 8 5 and 8 6 Page 8 7 4 Remove the bolts 18 washers 19 and nuts 6 from the steering rack assembly m...

Page 93: ...under the universal joint Use the wrench as a lever to pull the pinion from the housing Figure 8 10 Page 8 10 11 If the ball bearing 28 Figure 8 7 has been damaged remove the external snap ring 36 Fig...

Page 94: ...the bushing 7 Figure 8 7 Page 8 8 was removed install a new one Make sure that it is pressed in evenly See Figure 8 14 Page 8 12 Install the snap ring 8 Figure 8 7 Page 8 8 FIGURE 8 8 FIGURE 8 9 FIGUR...

Page 95: ...If the bearing 28 was removed press on a new bearing exerting all pressure on the inner race grease the bearing before installing it Then install the external snap ring 36 Figure 8 7 Page 8 8 7 If th...

Page 96: ...ft lbs 54 N m Figure 8 7 Page 8 8 14 Install the dust seal bellows 5 washer 32 and snap ring 31 Figure 8 7 Page 8 8 15 Install the dust seal bellows 35 and hex nut 11 Figure 8 7 Page 8 8 16 Install t...

Page 97: ...guide 13 Figure 8 17 Page 8 14 7 Remove the universal joint assembly from the pinion 8 by fully removing the bolt and then sliding off the universal joint TO BE SURE THAT THE RACK AND PINION IS WORKI...

Page 98: ...See Figure 8 8 Page 8 10 9 Using snap ring pliers remove the internal snap ring 11 Figure 8 17 See Figure 8 9 Page 8 10 FIGURE 8 17 IF THE DUST SEAL 12 IS REMOVED REPLACE WITH A NEW ONE 24 23 27 28 26...

Page 99: ...ure 8 17 3 Apply a liberal amount of grease to the teeth of the rack 17 then slide the rack through the bushing 5 and housing 6 Install the stop washer 18 and retaining ring 19 to the end of the rack...

Page 100: ...nd to the splined end of the steering column shaft 3 Align the flat portion of the steering shaft spline with the bolt hole in the universal joint and then slide the shaft into the upper universal joi...

Page 101: ...NECT BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG FRAME GROUND DO NOT ALLOW WRENCH OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHE...

Page 102: ...ach tire and the framing square See Figure 8 18 2 Loosen do not remove the four bolts 30 that secure the leaf spring 6 to the bottom spring plate 29 Figure 8 23 Page 8 23 3 Loosen do not remove the he...

Page 103: ...8 19 FIGURE 8 20 FIGURE 8 21 THE TIE ROD HAS RIGHT HAND THREADS ON ONE END AND LEFT HAND THREADS ON THE OTHER END RIGHT HAND THREADS ARE IDENTIFIED BY A GROOVE IN THE TIE ROD IF THE MINIMUM TURNING R...

Page 104: ...H OFF PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI TION AND REMOVE KEY PRIOR TO SERVICING DO NOT WEAR LOOSE CLOTHING REMOVE JEWELRY SUCH AS RINGS WATCHES CHAINS ETC BEFORE SERVICING VEHICLE ALW...

Page 105: ...T REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LBS 454 KG MINIMUM LIFTING CAPACITY DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION ALWAY...

Page 106: ...e spindles Figure 8 23 See Tie Rod and Drag Link Removal Page 8 16 3 Remove the nut 17 and lock washer 18 from the top of the king pin 26 Figure 8 23 4 Raise the A Plate clevis 16 from the the king pi...

Page 107: ...m Figure 8 23 5 Attach the ball joints to the spindle arm install and tighten the nut 33 and install the cotter pin 34 Figure 8 23 6 Install the front hub and wheel See Page 8 25 FIGURE 8 23 15 17 34...

Page 108: ...r to the vehicle frame Figure 8 22 Page 8 21 4 Remove the shock absorber SHOCK ABSORBER INSTALLATION 1 Install the shock absorber by reversing the removal procedure 2 Tighten the nuts to 18 22 ft lbs...

Page 109: ...ups 7 were removed press new ones in squarely against the stop in the hub 3 Install the wheel bearings 5 into the hub and install a new seal 6 with the metal edge toward the hub See NOTE below 4 Insta...

Page 110: ...Page 8 26 8 E G...

Page 111: ...om of the hole The lower plug is for draining the lubricant When draining the lubricant the level plug should be removed so that the lubricant will drain faster Be sure that the drain plug is installe...

Page 112: ...BATTERIES OR ELECTRICAL CON NECTIONS LIFT ONLY ONE END OF A VEHICLE AT A TIME BEFORE LIFTING LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR...

Page 113: ...ng 5 Figure 9 1 Page 9 1 If the bearing is damaged or worn replace it AXLE BEARING Removing the Axle Bearing 1 Place a bearing puller wedge attachment Club Car Part No 1012812 on the axle shaft betwee...

Page 114: ...R TO REMOVE IT FIGURE 9 5 FIGURE 9 6 APPLY LOCTITE 271 TO THE INSIDE OF THE COLLAR ONLY NOT TO THE SHAFT SO THAT THE LOCTITE WILL BE PUSHED AWAY FROM THE BEARING AS THE COLLAR AND BEARING ARE PRESSED...

Page 115: ...et the jackstands support the vehicle Figure 9 7 Page 9 6 BE SURE THAT THE RETAINING RING IS PROPERLY SEATED IN ITS GROOVE IF THE RING IS NOT PROPERLY INSTALLED THE AXLE ASSEMBLY WILL SEPARATE FROM TH...

Page 116: ...able rod end 1 from the shift lever and then remove the shifter cable assembly from the cable bracket 2 Figure 9 10 8 Remove the drive belt See Section 16 Page 16 3 9 Remove governor arm 3 governor ca...

Page 117: ...transmission See Section 16 Page 16 14 17 Remove the transmission from the transaxle See Section 17 Page 17 4 18 Drain lubricant from the transaxle as instructed on Page 9 1 19 Remove the axle shaft a...

Page 118: ...EVER IN THE NEUTRAL POSI TION AND REMOVE KEY PRIOR TO SERVICING MOVING PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRI...

Page 119: ...ning bolt Figure 9 26 Page 9 15 mount ing the motor to the transaxle 9 Carefullly remove the motor from the transaxle Slide the motor away from the transaxle until the motor spline becomes disengaged...

Page 120: ...d 9 Figure 9 1 See NOTE below 2 Remove the ten bolts 26 Figure 9 1 that hold the housing together 3 Pull the halves of the housing apart If necessary tap lightly with a rubber mallet on the spline of...

Page 121: ...r housing If necessary screw two of the hex bolts removed in step 9 2 back into the differential gear unit and while holding the unit slightly above the work bench tap lightly on the bolt heads Figure...

Page 122: ...erential cage gear See CAUTION below FIGURE 9 23 FIGURE 9 24 DO NOT REUSE BEARINGS AFTER REMOVING THEM REPLACE THEM WITH NEW ONES DAMAGED OR WORN GEARS SHOULD BE REPLACED AS SETS DO NOT PRESS AGAINST...

Page 123: ...keyway in the shaft and then press the large gear and the bearing 18 Figure 9 1 Page 9 1 onto the shaft Be sure that the key is properly positioned in the keyway before attempting to press on the larg...

Page 124: ...be 16 and 39 Figure 9 1 has been replaced the transaxle may need new shims To determine whether new shims are necessary the transaxle must be completely assembled except for the short axle tube 16 Fig...

Page 125: ...he clutches as instructed in Section 16 Page 16 4 16 Raise the vehicle enough to remove the jackstands then lower the vehicle to the floor Connect the plug wire to the spark plug and connect the batte...

Page 126: ...leaf spring eyes Secure them with lock nuts 8 Connect the brake cables 9 Install the shock absorbers Tighten shock absorber retaining nuts until the rubber bushings expand to the same size as the cup...

Page 127: ...OF A VEHICLE AT A TIME BEFORE LIFTING LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LBS 454 KG MINIMUM LIFT...

Page 128: ...TIME BEFORE LIFTING LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LBS 454 KG MINIMUM LIFTING CAPACITY DO NO...

Page 129: ...ed from the rim by hand REPAIRING A TIRE 1 Determine the location and cause of the air leak 1 1 Remove the wheel as instructed above and inflate the tire to no more than 20 psi 138 kPa 1 2 Immerse the...

Page 130: ...re that beads snap into place and form a proper seal as the tire is inflated See Figure 10 2 See WARNING below 7 Quickly remove the air nozzle and install the valve core 8 Adjust air pressure in the t...

Page 131: ...PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON NECTIONS LIFT ONLY ONE END OF A VEHICLE AT A TIME BEFORE LIFTI...

Page 132: ...fails to start 1 Fuel tank is empty Section 14 Fuel System 2 Fuel line or filters clogged Section 14 Fuel System 3 Fouled spark plug Section 13 Engine 4 Spark plug wire damaged Section 13 Engine 5 Lo...

Page 133: ...e fuel or incorrect rich fuel mixture Section 14 Fuel System 4 Igniter failed Section 12 Gasoline Vehicle Electrical System 5 Dirt entering combustion chamber Section 14 Fuel System 6 Rings worn out l...

Page 134: ...Starter generator belt is loose or slipping Section 12 Gasoline Vehicle Electrical System Starter generator 5 Voltage regulator failed Section 12 Gasoline Vehicle Electrical System Generator circuit 6...

Page 135: ...uel System Torque converter does not shift smoothly 1 Drive belt is worn cracked glazed or frayed Section 16 Torque Converter 2 Drive clutch malfunction Section 16 Torque Converter 3 Driven clutch mal...

Page 136: ...Page 11 6 11 G...

Page 137: ...PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI TION AND REMOVE KEY BEFORE SERVICING THE VEHICLE MOVING PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING ALWAYS USE INSULATED TOOLS...

Page 138: ...RCUIT FIGURE 12 2 THE STARTER CIRCUIT FIGURE 12 3 PAGE 12 4 BEFORE REMOVAL AND DISASSEMBLY CLEAN THE ENGINE ANY DIRT ENTERING THE ENGINE CARBURETOR OR OTHER PARTS WILL WORK AS AN ABRASIVE AND SHORTEN...

Page 139: ...circuit between the positive post of the battery and the F2 post of the starter The starter then turns and cranks the engine through belt driven pulleys FIGURE 12 2 BATTERY FRAME GROUND FRAME GROUND B...

Page 140: ...unt of charge going to the battery ENGINE IGNITION CIRCUIT The engine ignition circuit is independent of all other circuits except the kill circuit It consists of the igniter ignition coil spark plug...

Page 141: ...ot to leave the vehicle in reverse and to warn anyone in the area that the vehicle is in reverse The reverse buzzer circuit consists of a reverse buzzer reverse buzzer limit switch key switch the fuse...

Page 142: ...ed for the convenience of the trained and experienced mechanic If the neutral lock out cam is pulled out approximately 3 8 inch 10 millimeters and rotated one half turn until it snaps back into place...

Page 143: ...then check the specific gravity again If there still a 50 point difference replace the battery See Hydrometer Testing Page 12 49 FIGURE 12 11 FIGURE 12 12 DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOS...

Page 144: ...good one test the electrical circuits TESTING THE STARTER CIRCUIT AND THE GENERATOR CIRUIT Use the chart below Figure 12 13 as a starting point for troubleshooting problems with the starter and gen er...

Page 145: ...R REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 12 2 FOLLOW ALL PROCEDURES...

Page 146: ...L DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 12 2 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 12 1 FIGURE 12 15 DANGER WARNING ENGINE WILL NOT STOP RUNNING WHEN F...

Page 147: ...D REPLACE LIMIT SWITCH CONNECT WIRES CORRECTLY REPLACE WIRE CHECK CONTINUITY OF CIRCUIT WIRES TEST PROCEDURE 8 NO CONTINUITY ENGINE WILL NOT STOP RUNNING WHEN KEY SWITCH IS IN OFF POSITION CHECK KEY S...

Page 148: ...PAGE 12 1 FIGURE 12 17 DANGER WARNING REVERSE BUZZER WILL NOT FUNCTION GOOD FUSE CHECK REVERSE BUZZER LIMIT SWITCH TEST PROCEDURE 18 BAD FUSE USE MULTIMETER TO TEST LIMIT SWITCH REVERSE BUZZER WILL N...

Page 149: ...CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POI SON OIL LIGHT WILL NOT ILLUMINATE WHEN ENGINE OIL IS LOW CHECK WIRE CONNECTION TO THE OIL SENDING UNIT TEST PROCEDURE 20 CHECK LOW OIL WARNING LIGHT TE...

Page 150: ...RAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 12 2 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 12 1 FIGURE 12 19 WARNING CHECK NEUTRAL LOCK OUT LIMIT SWITCH TEST...

Page 151: ...eutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels 2 Set the multimeter to ohms Place the red probe on the A1 terminal of the s...

Page 152: ...lace the red probe on the common COM terminal green wire of the limit switch and place the black probe on the normally closed NC terminal orange wire of the limit switch 4 Make sure the battery is dis...

Page 153: ...the other large post Figure 12 23 Page 12 18 8 Connect the black cable to the battery negative post 9 Place the forward and reverse lever in NEUTRAL and place the neutral lock out cam in the SERVICE p...

Page 154: ...PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 12 2 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAG...

Page 155: ...qualified technician See Removal of the Starter Generator Page 12 27 An incorrect reading from A1 or A2 terminal indicates three possible problems 1 a grounded A1 or A2 terminal 2 a grounded wire in...

Page 156: ...e neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels 2 Check that the wires are connected correctly and are tight If they are...

Page 157: ...tached Place the black probe on the negative post of battery Turn the key switch to the ON position Depress the accelerator to start the engine and run it at full governed speed If the read ing is bet...

Page 158: ...al Place the black probe on the case The reading should be between 2 6 ohms If the reading is not correct replace the igniter Figure 12 30 3 The first test will find 90 of the bad igniters Some ignite...

Page 159: ...0 6 1 4 ohms replace the coil 4 Using a multimeter set on ohms measure the secondary coil resistance Place the red probe of the meter on the plug lead 3 and place the black probe on the core 2 Figure...

Page 160: ...st the engine kill circuit for a shorted wire or other failed components in the engine kill circuit See Testing the Engine Kill Circuit See Warning Below 6 If there is no spark or the spark is a faint...

Page 161: ...itch is being activated but the buzzer does not function place the red probe of the multime ter on one terminal and the black probe on the other terminal of the limit switch Without the lever depresse...

Page 162: ...en replace the oil light Test Procedure 22 Key Switch Starter Circuit 1 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the...

Page 163: ...uts 7 lockwashers 6 and bolts 5 from the mounting bracket 5 Remove the starter generator up through the access opening Disassembly of the Starter Generator to Service the Brushes 1 Remove the two bolt...

Page 164: ...NTACT BETWEEN THE BRUSHES AND COMMUTA TOR AS THE COMMUTATOR END COVER IS BEING REMOVED OR INSTALLED COULD POSSI BLY DAMAGE THE BRUSHES LIFT THE BRUSH SPRINGS OUT OF THE NOTCHES IN THE BRUSHES AND PULL...

Page 165: ...installed and possible damage to the brushes lift the brush springs out of the notches in the brushes and pull the brushes back from the center of the commutator end cover The springs will rest on the...

Page 166: ...Armature Commutator 1 Remove two bolts 20 and washers 21 and 22 and pull commutator end cover 23 free of the starter housing 24 Figure 12 39 Page 12 28 WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS W...

Page 167: ...clean cloth wipe the carbon dust off of the two bearings Inspect bearings by spinning them by hand and checking for both axial A and radial B play Figure 12 45 2 Replace the bearing if it is noisy doe...

Page 168: ...of the output end of the shaft Figure 12 44 Page 12 31 Removing the Field Coils 1 Remove the retaining nut from each field coil terminal and slide the insulator out of the slots in the housing Remove...

Page 169: ...tor bars Bruised or damaged armature core laminations Worn armature bearing or shaft Dirty or oily commutator Slight roughness of the commutator can be polished away with 400 or finer sandpaper DO NOT...

Page 170: ...g should be no continuity If the reading is incorrect replace the armature and the two bearings Figure 12 49 Visual Inspection of Field Coils If the insulation on the field coils appears blackened or...

Page 171: ...ess a new ball bearing onto the commutator end of the armature shaft 4 Install the output end cover 36 into the armature Secure the bearing retainer 32 to the cover using the three M5 x 18mm screws 43...

Page 172: ...rator Figure 12 50 1 Install the two 3 8 hex head pivot screws 5 into the mounting bracket with the heads of the screws fac ing towards the passenger s side of the vehicle Position the starter generat...

Page 173: ...tarter belt 3 around the pulley 10 on the end of the starter generator 1 Place the ten sion tool 13 Club Car Part No 1016867 between the starter generator and the starter generator mounting bracket 2...

Page 174: ...regulator 1 Figure 12 52 5 Disconnect the red wire from the solenoid and unplug the yellow wire from wire harness 6 Remove 18 gauge black wires 9 and 3 7 Remove the two hex nut 5 8 Remove regulator 1...

Page 175: ...f the center dash inward while pulling the top of the panel out and down 6 Slide center dash panel up the steering column by snapping out the top and then rotating the panel out and up There is suffic...

Page 176: ...hown Figure 12 1 Page 12 2 3 Remove electrical component box cover Figure 12 53 Page 42 4 Disconnect all the wires from the solenoid 5 Remove the two screws that secure the solenoid in place 6 Remove...

Page 177: ...elerator limit switch in place 6 Remove the accelerator starter limit switch Installing the Accelerator Starter Limit Switch Figure 12 53 Page 12 42 1 Install the accelerator starter limit switch 11 o...

Page 178: ...mmon COM terminal and the black wire to the normally open NO terminal of the kill limit switch 12 3 Install the accelerator starter limit switch 11 onto the two screws 16 Secure the switch in place us...

Page 179: ...n lbs 0 6 N m Place the forward and reverse lever in REVERSE position to make sure that both switches are actuated 2 Connect the black wire to common COM terminal the green wire to the normally open N...

Page 180: ...Disconnect the battery cables as shown Figure 12 1 Page 12 2 2 Remove the plastic cap covering the screw on each side of the center dash 3 Loosen but do not remove the screw on each side of the center...

Page 181: ...the frame and that the panel is properly seated and snapped in place REVERSE BUZZER LIMIT SWITCH Removing the Reverse Buzzer Limit Switch Figure 12 54 Page 12 43 1 Remove seat from the rear body 2 Di...

Page 182: ...r dash inward while pulling the top of the panel out and down 6 Slide center dash panel up the steering column by snapping out the top and then rotating the panel out and up There is sufficient slack...

Page 183: ...ter level See Water Level Figure 12 58 Page 12 50 4 Check the battery periodically to see that it is in a full state of charge See Battery Charging Page 12 52 5 Keep hold downs tight See Vibration Dam...

Page 184: ...ntly in hot weather or when the bat tery becomes old Mineral Content For the longest battery life distilled water should be used in the battery However if tap water is going to be used contact your lo...

Page 185: ...float rises off the bottom adjust the electrolyte level so that the float rides free of the bottom but does not strike the top of the glass tube Remove the hydrometer from the cell and release the pr...

Page 186: ...ined from the following table 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...

Page 187: ...Y EXPLOSIVE GASES KEEP SPARKS FLAMES CIGARETTES AWAY VENTILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE ALWAYS WEAR EYE PROTECTION WHEN WORKING ON OR NEAR BATTERY FOR ADDED PROTECTION COVER TOP OF...

Page 188: ...NOT EXCEED THIS 45 ANGLE WHEN LIFTING CARRYING OR INSTALLING THE BATTERY THE BATTERY ACID COULD CAUSE SEVERE PERSONAL INJURY WHEN ACCIDENTALLY COMING IN CONTACT WITH THE SKIN OR EYES OR COULD DAMAGE...

Page 189: ...ged and left in a cold environment can freeze and crack If the specific gravity drops below 1 220 the battery should be recharged 6 The frequency of recharging required will depend on the temperature...

Page 190: ...e is in the bottom of the electrical component box where the bolt secures the voltage regulator to the box The other end of this ground plate attaches through the side of the electrical box and is bol...

Page 191: ...LECTRICAL AND MECHANICAL 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...

Page 192: ...quired Edges DESCRIPTION PART NUMBER Gear Yoke 1016418 Compression Gauge and Adapter 1016410 02 Valve Spring Compressor 1016411 01 Valve Guide Reamer 1016412 01 Valve Guide Reamer Arbor 1016412 02 Pis...

Page 193: ...f used in an application for which they are not intended Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubrica...

Page 194: ...el end of the engine This will ensure proper adjustments ELECTRICAL SYSTEM 1 Always minimize shock hazards when working on electrical equipment Work in a clean dry environ ment with dry hands 2 The el...

Page 195: ...choid pump 3 Cartridge filter 5 Pressure relief valve 8 FIGURE 13 1 FIGURE 13 2 FIGURE 13 3 3 8 2 4 4 1 CUTAWAY VIEW OF CRANKCASE 5 9 9 8 11 10 12 13 3 7 2 6 1 OIL SUMP 2 OIL FILTER SCREEN 3 OIL PUMP...

Page 196: ...lug Use a 13 16 inch deep well socket wrench or 13 16 inch plug wrench to loosen the plug Spark Plug Cleaning Inspection and Repair Examine the plug Figure 13 4 The deposit on the plug base and electr...

Page 197: ...1 Install the plug gasket onto the plug then install the plug and thread it in until finger tight Tighten the spark plug to 20 ft lbs 27 N m torque ENGINE MOUNTING PLATE AND INNER FRAME See Rear Suspe...

Page 198: ...nuts at carburetor intake manifold 5 and remove manifold Figure 13 6 WHEN MAKING TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE KEY DO NOT ATTEMPT TO SERVICE HOT ENGINE...

Page 199: ...tem Section 15 10 If the engine is to be totally disassembled drain oil and remove the oil filter If only the cylinder head is to disassembled proceed without draining the oil or removing the oil filt...

Page 200: ...aft 5 out of the cylinder head Figure 13 10 3 Lift out the rocker arms 6 washer 7 and push rods 8 Figure 13 10 CYLINDER HEAD VALVES REMOVAL 1 Remove the six head bolts 1 and take off the cylinder head...

Page 201: ...13 13 5 Remove valve 10 Figure 13 13 6 If necessary remove valve stem seal with a screwdriver and replace seal FIGURE 13 11 FIGURE 13 12 THE SPRINGS SEATS 9 CAN ONLY BE REMOVED WITH THE VALVE STEM SE...

Page 202: ...ntake manifold Breather Valve Reed Valve Removal 1 Unscrew the mounting screw 1 and remove the back plate 2 and reed valve 3 Figure 13 15 See Page 13 21 for Installation CLEANING AND INSPECTION OF CYL...

Page 203: ...p drive the guide out of the head with the valve guide arbor 1 CLUB CAR Part Number 1016412 02 Figure 13 19 2 Install the snap ring 2 on the new valve guide Figure 13 20 3 Coat the guide with a light...

Page 204: ...e the cylinder head 2 Using Prussian Blue coat the valve seat 3 Push the valve into the guide 4 Rotate the valve against the seat with a lapping tool 1 Figure 13 22 5 Pull the valve out and check the...

Page 205: ...tter CLUB CAR Part Number 1016554 removing only enough material to produce a smooth and concentric seat Figure 13 24 2 5 Use a 32 seat cutter 1 CLUB CAR Part Number 1016555 to narrow the seat width to...

Page 206: ...th a fine lapping compound 4 2 Use the vacuum cup lapping tool 1 to grip the top of the valve Rotate the valve as shown to lap the valve to the seat Figure 13 26 4 3 Lift the valve slightly from the s...

Page 207: ...ead as shown Figure 13 28 2 If the valve head thickness A is less than 0 024 inches 0 610 millimeters replace the valve Valve Stem Bend 1 Support the valve in V blocks at each end of the stem Figure 1...

Page 208: ...Rocker Shaft 1 Using a telescoping gauge measure the inside diameter of each rocker arm bearing at several points along its length If the inside diameter is more than the service limit of 0 4754 inch...

Page 209: ...a dial gauge perpendicular to the rod Fig ure 13 34 2 Turn the rod slowly and read the variation on the gauge 3 If the push rod is bent more than 0 012 inch 0 3 millimeter replace the push rod CYLIND...

Page 210: ...evenly with hand 6 Use a torque wrench to tighten the six head bolts in the sequence shown Figure 13 37 7 Increase the torque in four increments of 50 in lbs 6 N m and then tighten to final torque of...

Page 211: ...on both valves BREATHER VALVE Visual Inspection 1 Inspect the reed valve 1 for sticking or binding Replace if necessary Figure 13 40 2 Inspect the reed valve for hairline cracks distortion or breakag...

Page 212: ...stall cotter pin 10 Install spring 12 onto the throttle spring bracket 13 and the throttle valve Mount the governor guard 8 Figure 13 42 9 Apply a light film of clean engine oil onto the seal of the n...

Page 213: ...Section 12 8 Remove starter generator See Electrical System Section 12 9 Remove drive belt See Torque Converter Section 16 10 Remove drive clutch See Torque Converter Section 16 FIGURE 13 41 FIGURE 1...

Page 214: ...s 3 and take off the crankcase cover 4 Figure 13 43 3 Disconnect the oil sending wire from the cord connection Remove the two mounting screws from the inside of the cover Remove the oil sending unit f...

Page 215: ...nnecting rod cap bolts 1 Figure 13 47 Page 13 26 2 Loosen the cap bolts and take them out together with the connecting rod cap 2 3 Push the piston connecting rod assembly out of the cylinder PISTON In...

Page 216: ...rs replace the piston 8 The oil ring is made of three pieces upper and lower rails and expander It is difficult to measure the ring groove clearance and thickness Inspect visually PISTON RING 1 Insert...

Page 217: ...millimeters replace the piston CONNECTING ROD IT IS DIFFICULT TO MEASURE EXACTLY THE OIL RING THICKNESS REPLACE THE OIL RING WHENEVER THE COMPRESSION RINGS TOP AND SECOND ARE REPLACED WHEN MAKING TES...

Page 218: ...length Figure 13 54 6 If the inside diameter exceeds 1 4003 inches 35 568 millimeters replace the connecting rod Piston and Connecting Rod Installation See Page 13 42 CYLINDER BLOCK While the engine i...

Page 219: ...r standard size 1 When the bore is resized to 0 010 inch over standard size the new bore dimension is 3 0791 3 0799 inches 78 210 78 230 millimeters When the bore is resized to 0 020 inch over standar...

Page 220: ...at the connector 2 Remove the two bolts 3 and take out the ignition coil Figure 13 58 3 Hold the flywheel 4 not the fan 7 with a strap wrench 5 and remove the flywheel nut 6 by turn ing it counterclo...

Page 221: ...millimeter Figure 13 60 3 Torque the two ignition coil bolts to 30 in lbs 3 4 N m OIL PUMP Removal 1 Remove the six screws 1 and take off the oil pump cover 2 Figure 13 61 2 Peel off the oil pump cov...

Page 222: ...7 inch 11 4 millimeters Figure 13 63 4 2 Using a micrometer measure the diameter of the outer rotor at several points Figure 13 64 4 3 If the rotor diameter is less than 1 5923 inches 40 444 millimete...

Page 223: ...g and burrs Replace it if necessary 4 Measure free length of the spring 3 with a vernier caliper Figure 13 68 4 1 If the free length of the relief valve spring is less than 0 748 inch 19 00 millimeter...

Page 224: ...cting rod opposite the crankpin Figure 13 71 3 Position the gear yoke with the side blocks positioned as close to the crankshaft as possible as shown Figure 13 71 4 Using a press push on the end of th...

Page 225: ...ing surfaces at several points Figures 13 73 and 13 74 1 2 If the inside diameter of the small end is greater than 0 4746 inch 12 057 millimeters replace the link rod Figure 13 73 ALWAYS USE A PRESS W...

Page 226: ...d with its seam 6 toward the side of the link rod with the hollow 5 and at right angles to the rod center to a depth of 0 039 inches 0 991 millimeters from the surface Figure 13 76 COUNTERBALANCE WEIG...

Page 227: ...e the crankshaft 4 Using a micrometer measure connecting rod journal at several points along its length Figure 13 80 5 If the journal diameter is less than 1 3954 inches 35 443 millimeters replace the...

Page 228: ...nd the crankshaft journal A Figure 13 83 2 The final finishing dimensions are as follows Figure 13 83 A 1 3775 1 3779 inches 34 989 35 00 millimeters B 0 110 0 126 inch 2 80 3 20 millimeters radius tw...

Page 229: ...l bearing by hand and check for A axial play and B radial play Replace the ball bearing if it is noisy does not spin smoothly or if it has any play Figure 13 86 Page 13 40 OIL SEALS Oil seals are used...

Page 230: ...Plain bearing surfaces are used for both ends of the camshaft and the flywheel end of the crankshaft Inspection 1 Inspect the camshaft surfaces one in the crankcase 3 and the other in the crankcase c...

Page 231: ...T BATTERY AS SHOWN FIGURE 12 1 PAGE 12 2 REMOVE SPARK PLUG WIRE BEFORE REMOVAL AND DISASSEMBLY CLEAN THE ENGINE SEE SAFETY WARNINGS PAGE 13 1 ALWAYS USE A PRESS WHEN REMOVING OR INSTALLING THE SPUR GE...

Page 232: ...iston head opposite the lettering MADE IN JAPAN 2 on the connect ing rod Insert the piston pin thorough the piston holes and the connecting rod Install the two retaining rings to hold the pin in place...

Page 233: ...Measure from the crankcase cover 3 mounting face to the crankshaft bearing inner end 4 Record measurement B Figure 13 94 3 Locate the measurements on the Crankshaft Shim Table Follow lines to where t...

Page 234: ...R SEATS IN THE SLOT 2 IN END OF THE CAMSHAFT FIGURE 13 98 IF THE OIL PUMP TANG IS NOT SEATED IN THE SLOT IN THE CAMSHAFT SERIOUS ENGINE DAMAGE WILL RESULT SEE NOTE AT TOP OF PAGE 13 45 Measurement B 1...

Page 235: ...ing the sequence tighten them to 240 260 in lbs 26 N m torque See Figure 13 99 IF THE OUTSIDE EDGES OF THE CAMSHAFT AND CRANKSHAFT GEARS ARE NOT FLUSH AND THE CRANKCASE COVER WILL NOT EASILY MAKE FULL...

Page 236: ...belt See Torque Converter Section 16 9 Install muffler See Exhaust System Section 15 10 Install starter generator and belt See Electrical System Section 12 11 Connect starter generator wires and the...

Page 237: ...Place neutral lock out cam in SERVICE position 25 Start engine and adjust RPM 26 If initial checks indicate engine is functional place neutral lock out cam in OPERATE position 27 Test drive car to in...

Page 238: ...bearing I D MAX 0 9079 in 23 063 mm Cylinder Bore I D Standard 3 0700 to 3 0708 in 77 980 to 78 000 mm Cylinder Bore I D MAX 3 0735 in 78 067 mm Cylinder Bore out of round MAX 0 0022 in 0 056 mm Crank...

Page 239: ...7 00 to 7 015 mm ITEM OVER SIZE LIMITS Final Boring Bore Diameter 0 010 in 0 25 mm 0 020 in 0 50 mm 3 0791 to 3 0799 in 78 210 to 78 230 mm 3 0890 to 3 0898 in 78 460 to 78 480 mm Final Bore Diameter...

Page 240: ...governed speed 45 5 psi 314 kPa Oil Filter bypass valve opening pressure 11 4 to 17 0 psi 78 to 118 kPa Compression Pressure MIN 156 psi 1076 kPa Crankcase Vacuum MIN at governed speed 1 18 in 30 mmH...

Page 241: ...OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL AND MECHANICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS...

Page 242: ...d metered through the pilot air jet The intake air draws fuel metered by the pilot jet 6 from the carburetor float chamber The combus tible mixture of air and fuel is then delivered into the venturi t...

Page 243: ...nd into the float bowl The fuel entering the bowl causes the float 4 Figure 14 4 to rise until it shuts off the inlet valve preventing the fuel from exceeding a level predetermined by the float level...

Page 244: ...e the fuel inlet valve could be worn or the valve may be dirty Another cause of this condition may be a damaged float that has filled with fuel and sinks For elevations above 3000 feet main jets other...

Page 245: ...R SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL AND MECHANICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS...

Page 246: ...TLE RETURN SPRING 11 MUST BE DISCONNECTED NOTE ITS PROPER ORIENTATION SO THAT IT CAN BE REPLACED WITH THE SAME ORIENTATION THE CARBURETOR MUST BE KEPT UPRIGHT DURING REMOVAL FIGURE 14 6 NOTE yy yy yy...

Page 247: ...DY WHEN THE FUEL BOWL IS REMOVED DURING NORMAL OPERATION THE FUEL BOWL RETAINS THE FLOAT PIVOT PIN 6 MAKE SURE THAT THE FLOAT PIVOT PIN DOES NOT FALL OUT OF THE CARBURETOR BODY AFTER THE FUEL BOWL IS...

Page 248: ...0 in lbs 0 90 1 13 N m 14 Install carburetor vent line 14 and clamp 13 15 Install the governor cable clevis pin 24 and spring cotter 25 16 Install the governor guard 6 Tighten the mounting screws to 1...

Page 249: ...ER IN THE NEUTRAL POSI TION AND REMOVE KEY BEFORE SERVICING THE VEHICLE DISCONNECT BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG LIFT ONLY ONE END OF A VEHICLE AT A...

Page 250: ...set the park brake to the first latch and pawl position and check for proper activation of switches 8 While pressing the accelerator pedal the following events should occur in exactly the order shown...

Page 251: ...clevis pin Item 8 and spring cotter 9 through the rear clevis and governor lever arm 5 With the governor lever arm loose on the governor shaft use a flat blade screwdriver to turn the gover nor arm s...

Page 252: ...OR CABLE FIGURE 14 11 ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE SOME KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL AND MECHA...

Page 253: ...nt on Page 14 14 7 Install the electrical box cover TURN KEY SWITCH OFF PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI TION AND REMOVE KEY BEFORE SERVICING THE VEHICLE MOVING PARTS DO NOT ATTEMPT...

Page 254: ...adjusted repeat step 6 8 If more adjustment is required than the cable housing will allow make sure that the spring on the other end of the cable is properly positioned Excessive belt and torque conv...

Page 255: ...ld be checked every year or 150 hours and replaced every two years or 300 hours More frequent service may be required in extremely dirty operating environments Need for immediate ser vicing will be in...

Page 256: ...NEUTRAL POSI TION AND REMOVE KEY BEFORE SERVICING THE VEHICLE FRAME GROUND DO NOT ALLOW WRENCH OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRICAL WIRING NEVE...

Page 257: ...e 14 18 2 1 Remove the clamps 16 and fuel lines 18 and 19 from the filter Figure 14 13 Page 14 18 2 2 To prevent draining of gasoline plug the fuel lines 18 and 19 Figure 14 13 Page 14 18 3 Remove the...

Page 258: ...N OF FUEL FLOW FROM TANK TO CARBURETOR THE ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS AND DEADLY POI SON DO NOT OPERATE THE ENGINE IN AN ENCLOSED AREA WITHOUT PROPER VENTILA TION FUEL LINE R...

Page 259: ...e fuel pump Figure 14 13 3 Disconnect the fuel lines 23 and 18 from the pump and plug them to prevent gasoline leaking CORRECT ANY FUEL LEAKS BEFORE OPERATING THE VEHICLE GASOLINE FLAMMABLE EXPLOSIVE...

Page 260: ...and back cover Be sure that the vent on the front cover is clean both inside and outside Figure 14 14 2 Inspect the valve assemblies 31 32 and 33 and all gaskets and diaphragms for tears or other dam...

Page 261: ...de of the fuel pump Figure 14 13 Page 14 18 3 Connect the impulse line 21 to the bottom nipple on the fuel pump Use a new clamp 20 Figure 14 13 Page 14 18 4 Install the fuel pump on the fuel tank and...

Page 262: ...at the seat back support and rear body from the vehicle See Section 5 2 Place the forward and reverse lever in the NEUTRAL position and the neutral lockout cam in the SER VICE position Disconnect the...

Page 263: ...entilated area set the tank upside down so that the water can drain out of it To make sure that the tank dries completely allow the tank to sit for 24 hours 4 Store the tank upside down with the cap i...

Page 264: ...condary fuel filter has an arrow indicating fuel flow direction and has a blue filter element inside of it Fuel line No 4 a black 2 1 4 inch fuel line runs from the outlet of the secondary fuel filter...

Page 265: ...VICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL MECHANICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION W...

Page 266: ...s shown 3 Position the muffler and bracket assembly and install the bolts 5 lock washers 4 and flat washers 3 Thread the bolts in only enough to support the muffler and bracket assembly Do not tighten...

Page 267: ...verse lever in the NEUTRAL position and the neutral lock out cam in the SER VICE position Start the engine and check for exhaust leaks and proper engine operation See DAN GER below GASOLINE FLAMMABLE...

Page 268: ...Page 15 4 15 G...

Page 269: ...vercomes the force of the centrifugal weights to close the driven clutch and open the drive clutch thus increasing axle torque with little or no change in engine RPM ONLY TRAINED TECHNICIANS SHOULD RE...

Page 270: ...r Club Car Part No 1014497 Drive Clutch Holder Tool Club Car Part No 1015524 Clutch Alignment Tool Club Car Part No 1014498 Driven Clutch Puller Plug Club Car Part No 1014507 Driven Clutch Cam Puller...

Page 271: ...SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL MECHANICAL REPAIR ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE WEAR A FULL FACE SHIELD WHEN W...

Page 272: ...S OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL MECHANICAL REPAIR FIGURE 16 2 MAKE SURE THAT FINGERS ARE NOT UNDERNEATH THE BELT WHEN ROLLING IT OFF OF THE DRIVEN CLUTCH IN STEP 1 ONLY TR...

Page 273: ...AYS BEFORE SERVICING DISCONNECT BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG BE VERY CAREFUL WHEN HANDLING THE CLUTCHES A CLUTCH THAT HAS BEEN DROPPED WILL NOT BE P...

Page 274: ...r and on the moveable face casting Figure 16 6 Page 16 8 2 Remove the clutch cover 1 Figure 16 5 2 1 Thread the center bolt of a Drive Clutch Hub Puller Club Car Part No 1014497 into the clutch until...

Page 275: ...age 16 9 4 1 Remove the screws flat washers drive button take up springs and drive buttons as shown Fig ure 16 8 5 Remove the clutch weights Figure 16 9 Page 16 9 5 1 Remove the screws and flat washer...

Page 276: ...sary Figure 16 5 8 If necessary remove the idler bearing Use a press to remove the bearing Figure 16 10 See NOTE below 9 Use a scribe to remove the spiral back up ring 12 Figure 16 5 Page 16 7 from ea...

Page 277: ...ORMAL FOR A SMALL AMOUNT OF GREASE TO BE PRESENT AT THE EDGE OF THE SEAL REMOVE THESE ITEMS FROM RIBS 10 24 SCREW FLAT WASHER DRIVE BUTTON DRIVE BUTTON TAKE UP SPRING RIBS WEIGHT SLOTS IN HUB CASTING...

Page 278: ...sively worn or damaged replace the entire fixed face drive assembly DRIVE CLUTCH ASSEMBLY 1 Press idler bearing 6 onto the hub of the fixed face assembly 7 Press on the inner race of the bear ing only...

Page 279: ...ry weights Figure 16 13 10 Install white plastic flat washers on each end of the mounting pins and push them against the outside surfaces of the weights Center the weights and washers on the mounting...

Page 280: ...18 and the mount ing washer 19 on the bolt 17 and start the bolt into the crankshaft Tighten the bolt to 23 28 ft lbs 31 38 N m Figure 16 5 Page 16 7 2 Install the starter generator belt and adjust be...

Page 281: ...O CONTACT FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRIC WIRING NEVER ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME ENGINE INNER FRAME OR OTHER METAL COMPONENT TO AVOID UNINTENTIONAL STA...

Page 282: ...s remove the retaining ring 4 Figure 16 19 2 Insert a puller plug Club Car Part No 1014507 into the shaft bore and use a driven clutch cam puller Club Car Part No 1014508 to remove the cam 5 from the...

Page 283: ...than 1 384 inches 35 15 mm the entire moveable face assembly must be replaced 5 Inspect the shaft of the fixed face assembly There should be no measurable wear Replace the shaft if it is worn scratch...

Page 284: ...ly 1 one third of a turn counterclockwise then press the cam 2 onto the fixed face assembly 7 Install the retaining ring 2 Figure 16 16 Page 16 13 8 While holding onto the cam tap the end of the fixed...

Page 285: ...t the engine mounting bolts must be loosened and the engine moved to bring the clutches into alignment per Step 6 7 Tighten the engine mounting bolts to 22 25 ft lbs 30 34 N m 8 Check clutch alignment...

Page 286: ......

Page 287: ...VE KEY BEFORE SERVICING THE VEHICLE MOVING PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR THE BATTERY OR ELECTRICAL CONNECTIONS FRAME GROU...

Page 288: ...t Section 4 Under normal operating conditions periodic adjustment to the system should not be required The top speed of the vehicle should be checked on a weekly basis to ensure proper operation of th...

Page 289: ...ssion with lubricant through level indicator hole Fill with 20 oz 80 90 WT API Class GL 3 or 80 90 WT AGMA Class 5 EP gear lubricant Figure 17 2 TRANSMISSION FIGURE 17 3 FIGURE 17 3 59 58 57 56 55 53...

Page 290: ...rtor Section 16 Remov ing the Driven Clutch Page 16 14 WHEN MAKING TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE KEY DO NOT ATTEMPT TO SERVICE HOT ENGINE OR EXHAUST DIS...

Page 291: ...vernor cable Figure 17 7 9 Rotate the transmission 180 from its mounted position so that the input shaft is facing the transaxle Figure 17 8 Raise input shaft of transmission up and over the starter g...

Page 292: ...input shaft thrust washer 61 and the input shaft reverse gear 62 Figure 17 11 6 Remove the main cluster and the shifter arm sub assembly Figure 17 12 FIGURE 17 10 FIGURE 17 11 DO NOT USE A SCREWDRIVER...

Page 293: ...igure 17 14 Page 17 8 6 Remove two screws 6 from governor arm shaft 18 and remove internal governor arm 7 Figure 17 14 Page 17 8 7 Remove lower retaining ring 14 from governor arm shaft 18 Figure 17 1...

Page 294: ...aft bore Figure 17 15 10 Remove upper two retaining rings from governor arm shaft 18 Figure 17 3 Page 17 3 11 Remove and discard oil seal 24 FIGURE 17 14 DO NOT USE EXCESSIVE FORCE WHEN REMOVING GOVER...

Page 295: ...press ram with an 11 16 inch diame ter arbor press against the end of the shaft to remove the bearing 38 thrust washer 39 forward gear 41 and thrust washer 43 Figure 17 3 Page 17 3 See Figure 17 17 W...

Page 296: ...RVICE HOT ENGINE OR EXHAUST DISCONNECT BATTERY AS SHOWN FIGURE 12 1 PAGE 12 2 REMOVE SPARK PLUG WIRE CLEAN TRANSMISSION BEFORE DISASSEMBLY SEE SAFETY WARNINGS PAGE 17 1 FIGURE 17 19 FIGURE 17 20 73 73...

Page 297: ...epared for the ball and spring to fly out of the sleeve shift arm because the spring will be compressed as the rod is moving out of the way 2 Remove shifter ball 69 and shifter spring 68 Figure 17 21...

Page 298: ...ng Figure 17 25 1 1 Remove flange nut 51 from cover 53 Figure 17 25 1 2 Press idler shaft 59 out Figure 17 25 1 3 Remove O ring 55 thrust washer 56 needle bearing 57 and reverse idler gear 58 from idl...

Page 299: ...sted worn if there is a crack or there is an abnormal color change in the metal of the bearing The bearing should be replaced if there is wear or pitting on the needle ball or rolling surface 3 Gears...

Page 300: ...e the outside diameter of the shift rod 71 at several points along its length and replace if the diameter is less than 276 inch 7 01 millimeters Figure 17 32 11 All oil seals that have been removed sh...

Page 301: ...he outside edge of the seal to assist installation Press oil seal 31 into the output shaft bore using transmission oil seal tool Club Car Part No 1014160 Oil seal should be flush with the outside cove...

Page 302: ...he center of the hub Hold the synchro inserts in place from underneath 3 Install the synchro spring 45 under the lip of all three synchro inserts Figure 17 19 Page 17 10 Install the other synchro spri...

Page 303: ...ully seated against Belleville spring and thrust washer Shifter Arm Assembly Figure 17 21 Page 17 11 1 Install roll pin 72 into shift rod 71 bore with pin protruding equally on both sides of rod appro...

Page 304: ...pply a light film of new transmission lubricant to the outer race of the bearing Then using a press sleeve that will apply pressure to only the outer race press the ball bearing 1 into the bearing sur...

Page 305: ...39 and 17 40 ASSEMBLY OF THE TRANSMISSION 1 If the existing O ring has been removed install a new O ring 23 in the groove on the shifter shaft 22 Figure 17 41 Page 17 20 2 Hold shifter arm lever 67 i...

Page 306: ...onent assemblies the outer race of the bearing on the end of the shaft without a spline in it and the end of the rod of the shift arm assembly without the roll pin Figure 17 42 9 When installing the m...

Page 307: ...shaft on the transaxle 2 Install the three 1 4 x 4 retaining bolts A B C and three washers through the forward and reverse shifter cable bracket 1 the transaxle and the transmission Use three nylon l...

Page 308: ...through governor cable rear clevis and governor lever arm Figure 17 6 Page 17 4 12 Adjust governor See Governor Adjustment Section 14 Fuel System 13 Install 20 ounces of 80 90 wt API class AGMA 5 EP...

Page 309: ...ry and under intake expansion chamber The cable contin ues on between the rear body and the back part of the expansion chamber to the transmission Figure 17 45 2 Install cable with retaining nut 22 an...

Page 310: ...e loosened and the ball joint 2 rotated in the proper direction to get the proper adjustment Figure 17 46 Page 17 23 For major adjustments the cable retaining nuts 22 must be loosened and adjusted Whe...

Page 311: ...RN 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 JEWELRY SUCH AS RINGS WATCHES CHAINS ETC BEFORE SERVICING...

Page 312: ...asher 15 from the lower mounting stud Figure 18 1 4 Compress the shock absorber to remove it INSTALLING SHOCK ABSORBERS 1 To install reverse the removal procedure 2 On the upper shock absorber mount t...

Page 313: ...rubber bushing 7 from the shock absorber Figure 18 1 Page 18 2 7 Remove the nuts 12 and lock washers 11 attaching the U bolt 9 to the retainer plate on the inner frame Figure 18 1 Page 18 2 8 Remove...

Page 314: ...he inner frame to the rear enough to allow removal of the snubber INSTALLING THE SNUBBER 1 Position new snubber on inner frame mounting tab and then reverse the removal procedure to com plete the inst...

Page 315: ...ting nuts properly torqued Keep the front end aligned and properly adjusted FIGURE 18 6 yy y y y y yy yy y y yy yy y y y y yy yy y yyyy yyyy yy yy y y yy y yy y y yy y y yy yy yy yy y y yy TYPICAL 4 P...

Page 316: ...Page 18 6 18 G...

Page 317: ...TREME CAUTION WHEN USING TOOLS WIRES OR METAL OBJECTS NEAR BAT TERIES A SHORT CIRCUIT AND OR SPARK COULD CAUSE AN EXPLOSION BATTERIES CONTAIN ACID THAT IS POISONOUS AND CAN CAUSE SEVERE BURNS BATTERY...

Page 318: ...is in the ON position the control circuit is complete The solenoid coil enclosed in the sole noid will then be activated and the solenoid power contacts will close allowing power to reach the V Glide...

Page 319: ...SWITCH WHITE WHITE ORANGE YELLOW GREEN GREEN BLUE BLUE BLACK BLACK G R A Y B L A C K BLACK BROW N PURPLE GRAY BROWN PURPLE GREEN GREEN RED RED WHITE WHITE YELLOW RED G REEN WHITE W H I T E BLACK BLAC...

Page 320: ...g for an adequate electrical connection If little or no drag is felt the receptacle or plug must be replaced If either the plug or receptacle is damaged or feels hot when charging one or both must be...

Page 321: ...olenoid Page 19 22 2 Vehicle will not run solenoid clicks F R Switch 1 Loose wires 2 Failed contacts Test Procedure 7 Solenoid 1 Failed contacts Test Procedure 10 V Glide Wiper Switch 1 Loose or broke...

Page 322: ...the closed position Accelerator Pedal Limit Switch Page 19 20 Accelerator Rod 1 Accelerator rod is bent or improperly adjusted Accelerator and Brake Pedal Group Section 6 V Glide Wiper Switch 1 Wiper...

Page 323: ...WHITE WHITE ORANGE YELLOW GREEN GREEN BLUE BLUE BLACK BLACK G R A Y B L A C K BLACK BROW N PURPLE GRAY BROWN PURPLE GREEN GREEN RED RED WHITE WHITE YELLOW RED G REEN WHITE WHITE BLACK BLACK GREEN GRE...

Page 324: ...components The probes will often be placed at points removed from the component being tested CONTROL CIRCUIT Test Procedure 1 Batteries Voltage Check 1 With the VOM set at Volts DC place the red probe...

Page 325: ...BLACK G R A Y B L A C K BLACK BROW N PURPLE GRAY BROWN PURPLE GREEN GREEN RED RED WHITE WHITE YELLOW RED G REEN WHITE WHITE BLACK BLACK GREEN GREEN RED RED ORANGE ORANGE RED RED WHITE WHITE WHITE BUL...

Page 326: ...mit Switch 1 Place the red probe of the VOM set at or continuity tester on the common terminal of the limit switch and place the black probe on the normally open NO terminal The reading should be cont...

Page 327: ...inal There should be no wire attached to the normally open NO terminal Test Procedure 5 Solenoid Activating Coil 1 Place the red probe of the VOM set at on one of the small activating coil posts of th...

Page 328: ...ce the black probe on the terminal of the heavy purple wire on the forward and reverse rotor 2 If the reading is incorrect at any position in Step 1 see Forward and Reverse Switch Page 19 32 Test Proc...

Page 329: ...ower On 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 FIG...

Page 330: ...Glide Wiper Switch 1 Read and heed the DANGER and WARNING boxes above LIFT ONLY ONE END OF A VEHICLE AT A TIME BEFORE LIFTING LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITAB...

Page 331: ...n to the wear limit line Figure 19 10 it must be replaced If the wiper arm brush is replaced see V Glide Wiper Switch Arm Adjustment Page 19 26 4 Make sure that all of the contacts are tight and that...

Page 332: ...Page 19 16 19A E...

Page 333: ...ULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE SOME KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNING...

Page 334: ...Insert a screwdriver at the top center of the center dash between the dash and cowl brace Gently pry the center dash out slightly from under the edge of the cowl brace 2 4 Pull the center dash out app...

Page 335: ...press the plastic cap into place on the outside of the center dash Figure 19 11 2 Connect the wires to the key switch terminals See Figure 19 2 Page 19 3 and then coat the termi nals with Battery Prot...

Page 336: ...k inspect the forward and reverse rotor and limit switch for damage ACCELERATOR PEDAL LIMIT SWITCH Testing the Accelerator Pedal Limit Switch See Test Procedure 4 Page 19 11 Removing the Accelerator P...

Page 337: ...es not check battery pack voltage battery wire connections and check continuity of the 10 gauge red wire 2 Place the black probe of a VOM set at volts on the large post of the solenoid with the 6 gaug...

Page 338: ...1 Remove the plastic cap covering the screw on each side of the center dash 2 2 Loosen but do not remove the screw on each side of the center dash panel 2 3 Insert a flat blade screwdriver at top cent...

Page 339: ...stors R1 R5 to the mounting board and then slide the resistors out from under the washers 3 Figure 19 13 Page 19 24 Installing the Resistors 1 Position the resistor ends under the washers 3 and tighte...

Page 340: ...ISTORS ARE CLOSER THAN ONE INCH TO THE RESISTOR SHIELD ADJUST THE RESISTORS IF A 3 1 2 HORSEPOWER MOTOR IS BEING USED IN CONJUNCTION WITH A V GLIDE WIPER SWITCH THE FOURTH AND FIFTH SPEED RESISTOR COI...

Page 341: ...RE INSTALLED IN THE PROPER ORDER FIGURE 19 13 PAGE 19 24 RESISTOR 1 HAS THE SMALLEST DIAMETER WIRE AND THE GREAT EST NUMBER OF COILS RESISTOR 5 HAS THE LARGEST DIAMETER WIRE AND THE SMALL EST NUMBER O...

Page 342: ...o be adjusted 3 To adjust surface contact remove the spring cotter pin 24 and turn the adjustment screw 14 until the surfaces of the wiper switch arm brush and fixed contacts are parallel Figure 19 15...

Page 343: ...e items must be properly adjusted If any one of them requires adjustment all of them must be checked and also adjusted if necessary in the order listed in the WARNING at the top of page 19 28 FIGURE 1...

Page 344: ...Install the arm brush wire terminal 34 onto the bolt 9 and then install the brass nut 3 Thread the nut against the arm brush wire terminal and tighten it to 35 45 in lbs 4 5 N m 8 Install the brass bo...

Page 345: ...bearings 8 Figure 19 15 tap them out from the back side with a punch Tap lightly V Glide Wiper Switch Assembly 1 Install bearings 8 into the wiper switch housing by tapping them lightly with a plasti...

Page 346: ...ion shim plate 29 on the I beam and then place the V Glide wiper switch assembly in position on the shim plate Install the mounting bolts 26 lock washers 27 and nuts 28 Figure 19 15 Page 19 27 Make su...

Page 347: ...m 10 Connect the 6 gauge black wire to the eighth contact from the bottom and tighten the nut to 35 45 in lbs 4 5 N m See WARNING and CAUTION below 11 Make sure the wiper switch and pedal group are p...

Page 348: ...17 for proper operation See Test Procedure 3 Forward and Reverse Anti arcing Limit Switch Page 19 10 See Test Procedure 7 Page 19 11 Removing the Forward and Reverse Switch 1 Remove the forward and re...

Page 349: ...rward and reverse switch label them so they will be recon nected properly Servicing the Forward and Reverse Switch 1 Keep the switch clean 2 If the forward and reverse switch is stiff or binds in oper...

Page 350: ...Page 19 34 19A E...

Page 351: ...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 ONLY TRAINED TECHNICI...

Page 352: ...batteries The OBC uses this data also to indicate possible battery or charging problems by illuminating a warning light in the dash For more information on the Battery Warning Light see Section 23 Pa...

Page 353: ...RCING FOR REVERSE 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...

Page 354: ...TE 18 BLUE 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 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 POTENTIOMET...

Page 355: ...ehicle movement by changing the direction of electrical current through the motor and thus the direction that the motor turns THE SPEED CONTROL CIRCUIT Multi step Potentiometer Wiper Switch Models The...

Page 356: ...ours Recharge batteries Check batteries Section 22 Check charger Section 23 Check OBC Page 20 20 OBC is defective Replace OBC No AC present Light remains on Light comes on intermittently when vehicle...

Page 357: ...d 1 Loose wires 2 Failed coil Test Procedure 5 Diode 1 Failed diode Diode Electrical Components Section 20 Page 20 32 Controller Electrical Leakage 1 Dirt or acid residue on the controller Test Proced...

Page 358: ...isconnected wires Electrical Components Section 20 B Page 20 28 2 Failed switch Electrical Components Section 20 B Page 20 28 5100 ohm Resistor 1 Resistor is disconnected or has failed Test Procedure...

Page 359: ...fully charged continued 4 Charger relay PowerDrive Charger Section 23 B 5 Charger fuse is blown PowerDrive Charger Section 23 B Charger On board Computer 1 Improper charging PowerDrive Charger Sectio...

Page 360: ...E E N 1 8 O R A N G E W 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 P...

Page 361: ...ELLOW 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 E N W H I T E 1 8 G R E E N W H I T E 1...

Page 362: ...ntinuously 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 white wire f...

Page 363: ...or pedal adjustment See Section 6 5 If the wires are connected correctly and the accelerator pedal is properly adjusted but the readings still are not correct replace the switch Vehicle with Continuou...

Page 364: ...B L A C K 18 RED WHITE 18 BLUE 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 LI...

Page 365: ...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 WHITE WHITE ON BOARD COMPUTER 10...

Page 366: ...ld 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 should read contin...

Page 367: ...erly adjusted then replace multi step potentiometer 5 Reconnect black and white wires to terminals 2 and 3 B and C as shown Figure 20 6 6 Reconnect half speed reverse resistor to half speed reverse li...

Page 368: ...USE THE VEHICLE TO RUN OVER YOU RESULTING IN SEVERE INJURY OR DEATH WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION FOLLOW ALL PROCEDURES EXACTLY AS STATE...

Page 369: ...inal 3 6 Reconnect batteries 4 Check for controller output 4 1 Make sure the batteries are connected 4 2 Remove the 6 gauge white wire from A2 motor terminal and secure it so that it cannot make con t...

Page 370: ...g properly attempt to drive the vehicle If the problem has been corrected the vehicle will function normally 4 If it is determined that computer lock up is not the problem it will be necessary to bypa...

Page 371: ...everse Limit Switch at its connection with the 18 gauge black wire from the multi step potentiometer See Figure 20 2 Page 20 3 2 2 With a multimeter set to ohms measure the resistance through the 18 g...

Page 372: ...emoved since initial vehicle start up This information is most useful in making sure that all vehicles in a fleet receive equal usage over long periods of time F4 Last charge termination type 1 incomp...

Page 373: ...data from the same or another on board computer Use the following procedure to review the data stored in the CDM 1 The value currently displayed will be F1 battery voltage 2 To view F2 press and hold...

Page 374: ...onnecting charger DC plug OBC is in a powerdown mode More than 75 EUs or 75 of energy removed from batteries OBC is bad OBC Will Not Communicate With The CDM On some 1995 PowerDrive System 48 vehicles...

Page 375: ...EDIATELY ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL REPAIR FOLLOW ALL PROCEDU...

Page 376: ...On vehicles manufactured on December 19 1994 and later serial numbers 9522 436452 and greater from the back of the dash panel push down on the retaining tabs surrounding the key switch and remove the...

Page 377: ...switch clean 2 If the switch is hard to turn or sticks a light spray of WD 40 may be applied to the contacts Installing the Forward and Reverse F R Switch Install switch in reverse order of disassemb...

Page 378: ...ck washers 4 and nuts 3 Label each wire prior to disconnecting wire terminals from each switch Installing Limit Switches Install in reverse order of disassembly Insert labeled wires on the common COM...

Page 379: ...the terminal of the resistor wire assembly onto the the half speed reverse limit switch ACCELERATOR ADJUSTMENT See Section 6 of this manual THE REVERSE BUZZER The reverse buzzer is mounted on the rear...

Page 380: ...he top and then rotating the panel out and up There is sufficient slack in the wiring to allow for this 6 Disconnect the orange wire from the reverse buzzer and also from F R limit switch No 2 Connect...

Page 381: ...teries Figure 20 1 Page 20 2 2 Discharge the controller See instructions in Warning Box on Page 20 25 3 Disconnect all wires from solenoid Remove resistor assembly and diode assembly BENDING THE TOP R...

Page 382: ...k for continuity 2 A diode is designed to conduct current in one direction only If a diode shows continuity in both direc tions or does not show continuity in either direction replace diode assembly I...

Page 383: ...ntroller See instructions in Warning Box on Page 20 25 3 Disconnect the 10 gauge black wire to OBC from the back of the charger receptacle Figure 20 15 4 Disconnect the gray wire from OBC at the sense...

Page 384: ...Page 20 2 2 Discharge the controller See instructions in Warning Box on Page 20 25 3 Remove all the 6 gauge wires connected to the controller Figure 20 16 4 Unplug the three 18 gauge wires plugged in...

Page 385: ...et 4 Use a phillips screwdriver to remove the four screws 9 from the bezel 7 and the three screws 12 from receptacle 2 Installing a New Receptacle Figure 20 17 1 Install the bezel 7 with four screws 9...

Page 386: ...link 6 from the charger receptacle Installing a New Receptacle Fuse Link Figure 20 17 Page 20 35 1 Insert the two fuse link mounting studs into the mounting holes in the charger receptacle 2 Place tw...

Page 387: ...m the key switch 6 Unplug the three pin connector 2 which connects the potentiometer to the wire harness Figure 20 18 7 Unplug the 18 gauge green white wire 3 from F R limit switch No 1 8 Remove the c...

Page 388: ...stalling the Continuously Variable Potentiometer Figure 20 18 1 Position the potentiometer housing 18 and pivot rod support 19 on the frame and install the four 1 4 bolts 17 with washers and nuts See...

Page 389: ...switch 9 Install the center dash panel in reverse order of removal 10 Connect the three pin connector 2 from potentiometer to the lead from the wire harness 11 Plug the 18 gauge green white wire 3 to...

Page 390: ...ometer 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 properl...

Page 391: ...1 Page 20 2 2 Remove center dash 2 1 Remove the plastic cap covering the screw on each side of the center dash 2 2 Loosen but do not remove the screw on each side of the center dash panel 2 3 Insert...

Page 392: ...to the brown wire female spade that was disconnected from the battery warning light Reading should be continuity If reading is incorrect repair or replace the wire 7 Disconnect the 18 gauge orange wh...

Page 393: ...IT 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 INTE...

Page 394: ...CEMENT MODULE Z1 Z14 F R 4 5 6 1 2 3 ORANGE WHITE GREEN GREEN RED RED BLACK RED GRAY BLUE GREEN GREEN W H ITE ORANGE GREEN BLUE W HITE YELLOW BLACK BLACK WHITE BLACK BLACK YELLOW WHITE WHITE W HITE GR...

Page 395: ...downhill the vehicle motor acts as a generator slowing the vehicle as it creates energy that is used to replenish the batteries when the on board computer senses that the batter ies are in a state of...

Page 396: ...h the green wire to the controller This signal tells the controller the vehicle s speed Z 14 Blue Wire from Forward and Reverse Switch Z7 transistor completes circuit from the forward and reverse swit...

Page 397: ...URE 21 6 PAGE 21 7 The capacitor charge circuit maintains a constant voltage supply to the three capacitors located inside the solid state speed controller This is a very low current that keeps the ca...

Page 398: ...WIRES MUST BE CLEAN AND PROPERLY CON NECTED IT IS NOT NECESSARY TO PUT THE FORWARD AND REVERSE SWITCH IN REVERSE AND DEPRESS THE ACCELERATOR TO DISCHARGE THE CAPACITORS THE CAPACITORS WILL DISCHARGE E...

Page 399: ...the Z4 Position on the controller The 18 Gauge Blue White Wire From the Z4 Z Plug Position to the Small Post on the Solenoid When the key switch is turned to the ON position the solenoid is activated...

Page 400: ...solenoid to the Forward and Reverse Rocker Switch No 2 terminal The 18 gauge blue wire from the Forward and Reverse Rocker Switch No 1 terminal to the Z7 position on the Z plug controller The Z6 tran...

Page 401: ...Controller Activating Circuit consists of The Key Switch The Accelerator Pedal Limit Switch Z8 Transistor located inside the controller The 18 gauge green wire from the large post of the Main solenoi...

Page 402: ...id consequently shutting off voltage to the Z3 position in the Z Plug The motor braking functions must be disabled before towing a PowerDrive Plus vehicle The Motor Braking Control Circuit consists of...

Page 403: ...engthening the pulses to the motor Shorter pulses result in lower speeds and longer pulses result in higher speeds FIGURE 21 10 FIGURE 21 11 BATTERY BANK 1 2 3 4 6 5 SOLENOID KEY SWITCH 1 2 CONTROLLER...

Page 404: ...e wire from the potentiometer to Z10 position on the Z Plug controller MOTOR SPEED SENSOR CONTROL CIRCUIT FIGURE 21 12 The Motor Speed Sensor Control Circuit monitors motor rpm to determine vehicle gr...

Page 405: ...h The potentiometer limit switch The dynamic braking transistor located in the Z5 Z plug controller position The forward and reverse rocker switch The connecting wires When the key switch is in the ON...

Page 406: ...replaceable in line fuse in the red wire from the solenoid The on board computer is not a field serviceable item If it fails the entire unit must be replaced BATTERY WARNING LIGHT CIRCUIT FIGURE 21 1...

Page 407: ...batteries have been disconnected and then reconnected the warning light will come on for 10 seconds when either the accelerator pedal is depressed or the charger DC cord is plugged in The Battery War...

Page 408: ...nual SOLID STATE SPEED CONTROLLER Unlike other speed control systems which control vehicle ground speed by varying the amount of voltage to the motor the PowerDrive Plus solid state controller always...

Page 409: ...When the vehicle is in motor braking mode the electric motor acts as a generator and produces an electrical current that is sent either to the batteries Regenerative Braking or to the energy displacem...

Page 410: ...ite wire and then on to the batteries through a 6 gauge black wire See Figure 21 18 Dynamic Braking Current produced by the motor from the A2 terminal on the motor travels through a 6 gauge white wire...

Page 411: ...e s battery circuit The contacts in the receptacle must grip the plug pins well enough to create enough pressure or drag for an adequate electrical connection If little or no drag is felt the receptac...

Page 412: ...ircuits can be found along with the general description of each specific circuit on pages 21 5 through 21 19 TEST Z PLUG POSITION 4 Z1 Red wire voltage input to controller 5 Z1 Red wire continuity 22...

Page 413: ...9 TEST OBC FUSES TEST PROCEDURE 15 REPLACE FUSES AS REQUIRED REPLACE OBC REPAIR OR REPLACE AS REQUIRED CHECK VOLTAGE TO MAIN SOLENOID COIL TEST PROCEDURE 7 TEST PROCEDURE 6 CHECK VOLTAGE TO MAIN SOLE...

Page 414: ...NG SOLENOID TEST PROCEDURE 28 CHECK CONTINUITY ON LARGE POSTS OF DYNAMIC BRAKING SOLENOID TEST PROCEDURE 28 CHECK Z PLUG POSITION AND CONTINUITY OF BROWN WIRE TEST PROCEDURE 27 CHECK CONTINUITY OF DYN...

Page 415: ...EPLACE AS REQUIRED CHECK FORWARD REVERSE ROCKER SWITCH TEST PROCEDURE 17 CHECK F R ROCKER SWITCH WIRE CONTINUITY TEST PROCEDURE 18 CHECK MOTOR WIRE CONTINUITY TEST PROCEDURE 38 ADJUST OR REPLACE POTEN...

Page 416: ...G FUNCTIONS TEST PROCEDURE 39 CHECK CONTROLLER VOLTAGE OUTPUT TO MOTOR SPEED SENSOR 3 WIRE PLUG TEST PROCEDURE 40 CHECK 3 WIRE PLUG CONNECTIONS TEST PROCEDURE 42 REPLACE CONTROLLER REPAIR OR REPLACE A...

Page 417: ...sition Green White Wire in Z plug 20 Accelerator Limit Switch Wire Continuity Green White and Blue Wires 21 Accelerator Limit Switch Continuity 22 Voltage at Z3 Orange White Wire Position in Z plug 23...

Page 418: ...ad 1 Place alligator clips Radio Shack Catalog No 270 354A or equivalent on the multimeter test leads Connect the red alligator clip to the positive post of battery No 1 and the black alligator clip t...

Page 419: ...et a multimeter to Volts DC then place the black probe on the negative post of battery No 6 and place the red probe on the positive post of battery No 1 Figure 21 21 The reading must be above 32 volts...

Page 420: ...Z1 Continuity Check 1 Turn the key switch to OFF and place the forward and reverse switch in NEUTRAL Disconnect the Z plug from the controller and disconnect the batteries 2 Place the black probe of a...

Page 421: ...e Z plug If all these components are good and still there is no voltage reading replace the controller Test Procedure 7 Voltage to Main Solenoid Coil 1 Turn the key switch to OFF and place the forward...

Page 422: ...center dash See Page 20 26 3 Place the black probe of a multimeter set to ohms on the large post of the main solenoid with the 6 gauge red wire attached and place the red probe on the key switch termi...

Page 423: ...a zero voltage reading with the key switch in the OFF postion or the solenoid does not click and there is no voltqge when the key switch is turned on check the batteries and connections Check continu...

Page 424: ...continuity If the reading is incorrect replace the solenoid 3 Turn the key switch to ON The solenoid should click and the reading should be continuity If the sole noid clicks and the reading is no con...

Page 425: ...om the negative terminal of the reverse buzzer 5 Connect a 18 gauge jumper wire to the positive terminal the reverse buzzer and connect the other end of the jumper wire to the positive post on battery...

Page 426: ...e the black probe of a multimeter set to ohms on the center terminal of the rocker switch black wire position and place the red probe on the terminal oriented toward the driver side of the vehicle ora...

Page 427: ...ER FUNCTION IF THE CHARGER DC CORD IS PLUGGED INTO THE RECEPTACLE AND THE KEY SWITCH IS ON THE CHARGER WILL CLICK ON AND OFF CONTINUOUSLY AT ONE SECOND INTER VALS AND THE AMMETER WILL GO TO 17 AMPS AN...

Page 428: ...d reverse switch in NEUTRAL Leave the batteries connected and disconnect the Z plug from the controller 2 Place the black probe of a multimeter set to Volts DC on the negative post of battery No 6 and...

Page 429: ...Place the black probe of a multimeter set to ohms on the center terminal of the rocker switch red white wire position and place the red probe on the terminal oriented toward the driver side of the veh...

Page 430: ...in Z Plug 1 Turn the key switch to OFF and place the forward and reverse switch in NEUTRAL Leave the batteries connected Disconnect the Z plug from the controller 2 Place the black probe of a multime...

Page 431: ...reading should be continuity If the reading is incorrect repair or replace the blue wire Figure 21 54 Test Procedure 21 Accelerator Limit Switch Continuity 1 Turn the key switch to OFF and place the...

Page 432: ...ug from the controller 2 Place the black probe of a multimeter set to ohms on the small post of the dynamic braking solenoid with the red and orange white wires attached and place the red probe in the...

Page 433: ...ltage from Z5 Brown Wire to the Dynamic Braking Solenoid Coil 1 Turn the key switch to OFF and place the forward and reverse switch in NEUTRAL Leave the batteries connected and leave the Z plug connec...

Page 434: ...ocedure 29 Energy Displacement Module FIGURE 21 61 FIGURE 21 62 DO NOT TOUCH THE ENERGY DISPLACEMENT MODULE IT MAY BE EXTREMELY HOT A HOT ENERGY DISPLACEMENT MODULE COULD CAUSE SEVERE BURNS FIGURE 21...

Page 435: ...uge green wire attached and place the red probe on the other end of the green wire at the energy displacement module The reading should be continuity If the reading is incorrect repair or replace the...

Page 436: ...the potentiometer See Section 20 Page 20 37 5 Turn the key switch ON and slowly depress the accelerator pedal until the accelerator limit switch clicks on and the red light in the CTM illuminates The...

Page 437: ...nector position in the Z plug Figure 21 69 Page 21 46 The reading should be continuity If the reading is incorrect repair or replace the purple wire Make sure that the purple wire is in the Z10 positi...

Page 438: ...ng snaps securely over the notches on the male plug housing 6 Pull gently on the two halves of the plug connection to ensure that they are fastened securely Test Procedure 36 Voltage from Controller t...

Page 439: ...the motor and place the red probe on the positive post of battery No 1 Figure 21 72 Page 21 48 The reading should be less than one volt 5 Turn the key switch ON place the forward and reverse rocker s...

Page 440: ...d probe on the F1 terminal blue wire on the controller The reading should be con tinuity If the reading is incorrect replace the blue wire 6 Place the black probe of a multimeter set to ohms on the F2...

Page 441: ...orrect inspect the motor speed sensor 3 wire plug and wires FIGURE 21 74 FIGURE 21 75 FIGURE 21 76 FIGURE 21 77 Club Car R CALIBRATION TEST MODULE INSTRUCTIONS SPEED CONTROL PEDAL CIRCUIT TEST POT CAL...

Page 442: ...ard and reverse switch in NEUTRAL Disconnect the bat teries Leave the Z plug connected to the controller 2 Place the black probe of a multimeter set to ohms in the female terminal of the black wire in...

Page 443: ...the bullet connector At approximately 2 inches from the on board computer puncture the insulation on the yellow wire with the point of the red probe Figure 21 79 The tester should show continuity 4 I...

Page 444: ......

Page 445: ...WATER FOLLOW WITH MILK OF MAG NESIA OR VEGETABLE OIL CALL A PHYSICIAN IMMEDIATELY EYES FLUSH WITH WATER FOR FIFTEEN MINUTES CALL PHYSICIAN IMMEDIATELY ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE T...

Page 446: ...of the case 2 Figure 21 81 Page 21 51 Installing the Forward and Reverse F R Switch Install switch in reverse order of disassembly REVERSE BUZZER Testing the Reverse Buzzer Circuit See Test Procedure...

Page 447: ...d torque to 66 in lbs 7 5 N m The solenoid does not have to be oriented in any particular manner Figure 21 82 or 21 83 FIGURE 21 82 FIGURE 21 83 TURN THE KEY TO OFF PUT THE FORWARD AND REVERSE SWITCH...

Page 448: ...ted in any particular manner Figure 21 82 or 83 Page 21 55 2 Install the wires on the solenoid as shown in wiring diagram Figure 21 1 Page 21 2 ON BOARD COMPUTER OBC Testing the On board Computer See...

Page 449: ...on the controller Figure 21 1 Page 21 2 6 Remove the 6 gauge and 10 gauge black wires from the B of the controller Figure 21 1 Page 21 2 7 Remove the two 1 4 lock nuts holding the OBC 8 Remove the OB...

Page 450: ...t Procedure 31 Page 21 43 Removing the Battery Warning Light See Removing the Battery Waning Light Page 20 41 Installing the Battery Warning Light See Installing the Battery Warning Light Page 20 42 E...

Page 451: ...Page 21 59 E 21B FIGURE 21 85 2 4 5 7 8 1 9 6 5 4 3...

Page 452: ...Page 21 60 21A E...

Page 453: ...VOID 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...

Page 454: ...e specifically designed to handle this type of service The rechargeable lead acid battery is a device for turning chemical energy into electrical energy and vice versa The main active elements within...

Page 455: ...but it does identify some of the common misconceptions and problems PROBLEM MISCONCEPTION AND REALITY 1 Deep Discharge Misconception This car can handle another 9 holes it has gone only 36 holes today...

Page 456: ...ERE 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 VE...

Page 457: ...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 build up on or around...

Page 458: ...l rise during charging and some of the electrolyte may bubble out of the cap This reduces its capacity and corrodes the metal parts around it The water level should be checked weekly to be sure water...

Page 459: ...nents and can reduce the capacity of the battery The batteries should be charged every day they are used even if only for ten minutes or after nine holes However the batteries should not be charged if...

Page 460: ...ries are put on charge an AC line problem exists The electrical service to your car storage facility should be sufficient to deliver 115 volts minimum 105 volts maximum 128 volts and 10 7 amps per cha...

Page 461: ...not within 0 5 volts of those batteries above 7 0 volts replace battery If readings are below 7 0 volts but within 0 5 volts of each other the batteries are old However they may have enough capacity l...

Page 462: ...e above 42 volts 36 V Reading below 6 amps and on charge set voltage above 56 volts 48 V No apparent problems Possible old batteries Go to hydrometer testing All readings above 7 0V and within 0 5V 36...

Page 463: ...to the cell Slowly release the bulb drawing electrolyte up into the glass tube of the hydrometer 5 When the float rises off the bottom adjust the electrolyte level so that the float rides free of the...

Page 464: ...0 012 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 Discharged Battery...

Page 465: ...ls 2 Connect the tester leads to the positive post of battery No 1 and negative post of battery No 6 See Figure 22 10 for V Glide 36 volt vehicle Figure 22 11 for PowerDrive System 48 vehicle BATTERY...

Page 466: ...me is 60 minutes or higher the problem is not with the batteries 2 If discharge times are low less than 60 minutes replace all batteries below 5 0 volts 36 V or below 6 7 volts 48 V ALWAYS WEAR FULL F...

Page 467: ...erformed and the following results were recorded V Glide 36 Volt Vehicle BATTERY VOLTAGES BATTERY CONDITION 1 2 3 4 5 6 5 25 5 25 5 25 5 25 5 25 5 25 EXCELLENT 5 3 5 3 5 4 4 9 5 3 5 3 BATTERY NO 4 IS...

Page 468: ...2 Car No 70 was also suspected of having a bad battery due to its performance The battery charger test showed 7 0 amps after a full charge After confirming that there were no problems with the electri...

Page 469: ...o be recharged every few weeks 5 Check the state of charge periodically Batteries that are discharged and left in a cold environment can freeze and crack If the specific gravity drops below 1 220 the...

Page 470: ...Figure 23 31 Page 23 43 and Figure 23 36 Page 23 50 6 Disconnect the transformer wire 4 from the relay and then connect this wire to the open terminal on the circuit breaker Figure 23 31 Page 23 43 a...

Page 471: ...ve 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 DO NOT LEAVE THE VEHICLE UNATTENDED...

Page 472: ...Page 22 20 22 E...

Page 473: ...versus time and shuts off when the batteries are fully charged As long as the charger is allowed to shut off by itself overcharging and under charging should be prevented Figure 23 1 See WARNING below...

Page 474: ...BLACK TO BATTERIES D C CORDSET WHITE ORANGE BROWN BLACK BLACK GREEN GREEN CASE GROUND WHITE TAN TAN CAPACITOR A C INPUT PLUG A C CORDSET ELECTRONIC TIMER ASS Y CONTROL CABLE ASS Y 1 2 3 4 5 1 2 3 4 FU...

Page 475: ...e AC line to which the charger is to be connected must be capable of supplying at least 15 amperes to each charger To reduce the risk of electric shock this battery charger must be grounded The charge...

Page 476: ...ER IF IT HAS RECEIVED A SHARP BLOW WAS DROPPED OR OTHERWISE DAMAGED IN ANY WAY CHECK IT TO BE SURE THAT IT IS OPERATING PROP ERLY BEFORE PUTTING IT BACK IN USE DO NOT ALLOW CLOTHING BLANKETS OR OTHER...

Page 477: ...charge rate and lower line voltages reduce the initial charge rate CHARGE BATTERIES ONLY IN A WELL VENTILATED AREA DO NOT LEAVE THE DC CORD PLUGGED INTO A VEHICLE RECEPTACLE WHILE UNAT TENDED FOR MORE...

Page 478: ...onnection between plug and receptacle Test Procedure 1 4 DC plug and cord Test Procedures 1 and 5 5 Electronic Timer Kit malfunction Test Procedure 2 6 On board receptacle fuse link is blown Page 23 2...

Page 479: ...he receptacle 6 Charger output is low 1 One diode failed Test Procedure 4 A 2 Transformer coil short circuit failure Test Procedure 7 7 Charger turns off too soon 1 AC power supply was shut off Test P...

Page 480: ...er a 2 to 5 sec ond delay the charger should start If the charger starts immediately no 2 to 5 second delay the Elec tronic Timer Relay has failed FIGURE 23 6 FIGURE 23 7 HIGH VOLTAGE WITH THE CHARGER...

Page 481: ...uity Check of AC Circuit 1 Check to be sure that the AC cord is securely plugged into a live AC outlet 2 Check the AC line fuse or circuit breaker in the storage facility 3 Insert the probes of a VOM...

Page 482: ...r single diode failures and testing of diodes If both diodes have failed use Test Procedure 4 B FIGURE 23 8 HIGH VOLTAGE WITH THE CHARGER ON THE VOLTAGE OF THE CAPACITOR INSIDE THE CHARGER IS APPROXIM...

Page 483: ...k all three fuse connections inside the charger to be sure that they are clean and tight It is possi ble that a loose internal fuse connection could create enough heat to cause a single fuse link to m...

Page 484: ...ontinuity should be observed in only one direction If the circuit shows no continuity in either direction and the fuse is good check individually the continuity of the DC plug and cord Test Procedure...

Page 485: ...tor is open or shorted it must be replaced TEST PROCEDURE 7 Transformer HIGH VOLTAGE WITH THE CHARGER ON THE VOLTAGE OF THE CAPACITOR INSIDE THE CHARGER IS APPROXIMATELY 650 VOLTS USE EXTREME CAUTION...

Page 486: ...r to supply AC power directly to the transformer coil the relay must be bypassed Refer to the Test Procedure 2 FIGURE 23 13 DO NOT ALLOW THE SECONDARY COIL LEADS TO TOUCH EACH OTHER THERE ARE APPROXIM...

Page 487: ...ee Test Procedure 6 If the voltage readings are correct both the transformer and the capacitor are good refer to Test Procedure 5 for further tests of the DC circuit TEST PROCEDURE 8 Battery State of...

Page 488: ...on only the ground blade If you show conti nuity on the flat blades or show no continuity on the ground blade the AC cord and plug must be replaced DC Cord and Plug 1 Disconnect the black wire of the...

Page 489: ...or terminals 3 2 Place the tester probes on the capacitor coil leads The reading should be continuity If the read ing is no continuity replace the transformer Relay 1 Disconnect the two black wires fr...

Page 490: ...OLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE OR CHARGER WEAR A FULL FACE SHIELD WHEN WORKING W...

Page 491: ...C Cord 1 Insert the leads of the new cord through the hole in the charger base 2 Make sure the red wire of the electronic timer is on the middle terminal of the heat sink assembly then place the white...

Page 492: ...10 12 in lbs 1 1 1 4 N m RECEPTACLE REPLACEMENT Removing the Receptacle Figure 23 16 1 Disconnect the small black wire 15 and the white wire 14 to the negative battey post from the neg ative terminal...

Page 493: ...23 4 Page 23 3 Receptacle Fuse Link Disassembly Figure 23 16 1 Remove the two screws 5 and then the lens 6 2 Remove the outer nuts 12 lockwashers 16 and wires 9 10 and 11 3 Remove the remaining nuts 8...

Page 494: ...ross the DC plug should indicate zero volts No transformer hum should be heard 2 Unplug the AC cord from its outlet and connect the DC plug to the receptacle The relay on the elec tronic timer kit sho...

Page 495: ...WORKING NEAR CAPACITOR TERMINALS ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS CHARGER ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL...

Page 496: ...ransformer lead tan to the top connector of the heat sink assembly 5 Install the charger cover 6 Check the charger for proper operation TRANSFORMER Removing the Transformer 1 Remove the charger cover...

Page 497: ...20 24 in lbs 2 3 2 7 N m 6 Connect the capacitor coil leads to the capacitor 7 With the wire tie removed in step 6 of Removing the Transformer tie the wires together as they were before the wire tie w...

Page 498: ...nsformer leads and the bus bar from the back of the fuse link assembly 3 Remove the fuse link retaining screws from the face of the charger and remove the fuse link assembly Installing the Fuse Link A...

Page 499: ...s been returned to the batteries rather than sensing voltage rate or change of voltage gassing point or any other measure ment parameter POWERDRIVE SYSTEM 48 CHARGING FEATURES INCLUDE Charge Interlock...

Page 500: ...in memory the amount of charge needed to fully replenish the batteries and will complete the charge during the next charge cycle When the charger is unplugged the warning light will come on and remain...

Page 501: ...ORE SERVICING VEHICLE ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON NECTIONS TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE DISCONNECT BATTERIES AS SHOWN IN FIGURE 22 6 PAGE...

Page 502: ...CHARGER PLUG TO THE VEHICLE RECEPTACLE GRASP THE PLUG AND PUSH IT STRAIGHT INTO THE RECEPTACLE DO NOT ROCK OR BEND IT TO DISCONNECT THE CHARGER FROM THE VEHICLE RECEPTACLE GRASP THE PLUG AND PULL IT S...

Page 503: ...MATERIALS AND VAPORS DO NOT USE NEAR FUELS GRAIN DUST SOLVENTS THINNER OR OTHER FLAMMABLES KEEP CHARGER DRY DO NOT EXPOSE TO RAIN FOR STORAGE KEEP THE CHARGER INDOORS CONNECT CHARGER ONLY TO A PROPERL...

Page 504: ...disconnected from the receptacle insert the AC cord into an outlet The charger relay should NOT close A multimeter set on DC volts and connected across the DC plug positive and negative pins should i...

Page 505: ...ltage toward the end of a charge cycle should be approximately 59 to 63 volts TO START CHARGE CYCLE 1 Remove the DC plug from the vehicle s charger receptacle 2 WAIT 20 SECONDS and then plug the DC co...

Page 506: ...ocedures specified in these charts can be found on the pages immediately following the charts FIGURE 23 23 RED WIRE OF D C CORD RED WIRE TO RELAY SECONDARY COIL LEADS TAN SECONDARY COIL LEADS BLACK DC...

Page 507: ...MOVE D C CORD FROM RECEPTACLE DISCONNECT BATTERY LEAD AND DISCHARGE CONTROLLER RECONNECT BATTERY B LEAD AND CHARGE BATTERIES DOES CHARGER COME ON CHECK SENSE LEAD FUSE TO SEE IF BLOWN NO YES YES NO NO...

Page 508: ...r hums but ammeter does not move 1 Blown charger fuse Test Procedure 4 B 2 Both diodes failed Test Procedure 4 B 3 On board computer malfunction Test Procedure 2 4 Failed transformer Test Procedure 6...

Page 509: ...led Test Procedure 4 A 2 Transformer coil short circuit failure Test Procedure 6 3 On board computer malfunction Test Procedure 2 8 Charger turns off too soon 1 AC power supply was shut off Test Proce...

Page 510: ...volt age of the battery pack must be over 36 volts DC in order to allow the on board computer to close the charger relay Figure 23 25 If battery pack voltage is too low to start charger see Charging B...

Page 511: ...rongs into outlet voltage should be 105 to 128 volts If proper voltage is not present have building wiring checked by a licensed electri cal contractor 5 Unplug the AC power supply cord from its outle...

Page 512: ...e again and note the reading Figure 23 28 A diode is designed to conduct current in one direction only if a diode conducts current shows continuity in both directions the complete rectifier assembly w...

Page 513: ...nks will blow whether or not the AC cord is plugged into an outlet 3 Although this is rare both diodes may fail as the result of a lightning strike at the charging location 4 Excessive heat due to a l...

Page 514: ...ging or shorting of adjacent coil turns If the transformer has failed a low or complete lack of output would be observed on the ammeter however the transformer may hum A blown AC line fuse or circuit...

Page 515: ...Test Procedure 5 for further tests of the DC circuit TEST PROCEDURE 7 Battery State of Charge Test 1 After the charger has shut off disconnect the DC charger plug for approximately 20 seconds and then...

Page 516: ...hould be shown on only the ground prong If continuity is shown on either of the flat prongs or is not shown on the ground prong the AC cord and plug must be replaced 5 Disconnect the white wire 5 from...

Page 517: ...er continuity cord and plug must be replaced 11 Move the alligator clip to the blue wire of the DC cord Check for continuity at the middle prong it should read continuity Transformer The PowerDrive ba...

Page 518: ...aced when worn or damaged If charger plug and receptacle show signs of corrosion or are becoming difficult to insert and remove the receptacle contacts and plug pins can be cleaned with a good electri...

Page 519: ...e nuts and bolts which secure the rectifier assembly to the case Tighten the bolts to 12 15 in lbs 1 4 1 7 N m 2 Connect the red wire from the DC cord and the red wire from the charger relay to the ce...

Page 520: ...to 20 24 in lbs 2 3 2 7 N m 5 Connect the other 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 t...

Page 521: ...e fuse link assembly 3 Remove screws from the front of the charger and remove the fuse link assembly Installation of Fuse Link 1 Place plastic cover over fuse assembly and install mounting screws from...

Page 522: ...ed to circuit breaker 4 With a pair of pliers squeeze in the retaining tabs on the sides of the circuit breaker and remove the cir cuit breaker through its mounting hole in the face of the charger Ins...

Page 523: ...t the black white and green leads of the new AC cord into 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 gr...

Page 524: ...Page 23 52 23A E...

Page 525: ...ould be no continuity If the readings are incorrect the motor will need to be removed from the vehicle and repaired by a qualified technician See Motor Removal Page 24 3 ONLY TRAINED TECHNICIANS SHOUL...

Page 526: ...in a brush assembly and or open armature windings may be the cause The motor will need to be removed from the vehicle and repaired by a qualified technician See Motor Removal Page 24 3 TEST PROCEDURE...

Page 527: ...AND EXPERIENCE IN GENERAL 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...

Page 528: ...E DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL ALWAYS WEAR SAFETY GL...

Page 529: ...ds 27 and 28 to identify their positions in the stator shell and winding assembly and then remove the nuts 6 and flat washers 5 Figure 24 8 Page 24 7 From the outside push the studs through the stator...

Page 530: ...irty or oily commutator should be cleaned and wiped dry Faults seen during the inspection can aid in determining the original cause of failure Slight roughness of the commutator can be polished smooth...

Page 531: ...Page 24 7 E 24 FIGURE 24 8 24 25 1 2 3 4 6 8 16 15 7 14 13 22 23 12 9 17 20 18 TYPICAL 3 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES 11 10 5 19 26 21 27 28...

Page 532: ...sition that the spring would be if a new brush were installed Figure 24 9 Inspection of the Bearing 1 Using a clean cloth wipe the carbon dust off of the bearing Inspect the bearing by spinning it by...

Page 533: ...CLUB CAR PART NO 1012811 WHEN USING A PRESS TO REMOVE BEARING FROM ARMATURE SHAFT USE AN ARBOR WITH AN O D OF LESS THAN 5 8 TO REMOVE BEARING USE PRESS AND WEDGE ATTACHMENT TOOL CLUB CAR PART NO 1012...

Page 534: ...until they are wedged under the bottom edge of the guide ring Remove the guide ring by quickly and forcefully slid ing the ram up the tool shaft and against the stop Figure 24 12 Page 24 9 See NOTE be...

Page 535: ...RETAINER 16 FIGURE 24 8 PAGE 24 7 IS POSITIONED ON THE ARMATURE SHAFT BEFORE THE BEARING IS PRESSED ON AN ARBOR WITH AN OUTSIDE DIAMETER OF LESS THAN 5 8 INCH 16MM SHOULD BE USED TO PRESS THE BEARING...

Page 536: ...See NOTE below 7 Align the matching marks on the end shield and the housing with winding assembly then install the four screws 8 Figure 24 8 Page 24 7 Tighten the screws to 80 100 in lbs 9 11 3 N m 8...

Page 537: ...aft Figure 24 17 5 Using a torque wrench tighten the lower 1 4 inch screw C Now tighten the screw A across from the first screw then tighten the center screw B at the top Tighten these screws to 60 70...

Page 538: ...the vehicle and finish tightening lug nuts using a criss cross pattern to 55 ft lb 74 6 N m See Figure 22 5 or 22 6 Page 22 5 12 Reconnect the battery cables negative first and tighten to 110 in lb 1...

Page 539: ...two leaf springs that are controlled by two shock absorbers mounted between the springs and the vehicle frame No adjustment or alignment is required FIGURE 25 1 1 2 TYPICAL 2 PLACES TYPICAL EACH SIDE...

Page 540: ...INED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL MECHANICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND H...

Page 541: ...e 25 5 Page 25 4 7 Remove the nut 3 and bolt 2 attaching the front of the leaf spring to the vehicle frame The spring can now be removed Figure 25 1 Page 25 1 8 Inspect the bushings 4 and spacers 5 in...

Page 542: ...O LOCK WASHERS 15 AND TWO NUTS 16 TIGHTEN BOTH NUTS 16 FINGER TIGHT THEN TIGHTEN THEM IN SEVERAL STEPS ALTERNATING FROM ONE TO THE OTHER TO 15 20 FT LBS 20 27 N M TIGHTEN THE SHOCK ABSORBER MOUNTING N...

Page 543: ......

Page 544: ...Golf Cars Club Car Inc P O Box 204658 Augusta GA 30917 4658...

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