Club Car 1998 DS, Maintenance And Service Manual Supplement

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ELECTRICAL COMPONENTS Multi-step Potentiometer
1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 12-13
12
5. Connect the six-pin connector to the wire harness at the multi-step potentiometer.
6. Connect the accelerator rod (1) to the potentiometer (Figure 12-9, Page 12-12) .
7. Make sure wiper contact is positioned squarely on the last stationary contact when the accelerator pedal is
depressed; otherwise, top vehicle speed will not be achieved.
8. Make sure wiper switch and pedal group are properly adjusted. See Section 5–Accelerator and Brake Pedal
Group in the Maintenance and Service Manual.
9. Install and connect the No. 5 and No. 6 batteries leaving the No. 6 negative (–) post disconnected. Tighten terminals to
110 in.lb (12.4 N-m).
10. Reconnect battery cables to battery No. 1 positive (+) first, then connect cable to battery No. 6 negative (–). Tighten
terminals to 110 in.lb (12.4 N-m). Place the Tow/Run switch in the RUN position.
11. Drive the vehicle and inspect it for proper operation.
MULTI-STEP POTENTIOMETER ARM ADJUSTMENT
The contact surfaces on the multi-step potentiometer arm brush and fixed contacts must be parallel to ensure efficient
operation of the multi-step potentiometer
(Figure 12-10, Page 12-14) . Adjust arm contact as follows:
1. Place Tow/Run switch in the TOW position and disconnect battery cables, negative cable first (Figure 12-1,
Page 12-2) . Remove the No. 5 and No. 6 batteries from the vehicle and remove the cover from the multi-step
potentiometer.
2. Test the multi-step potentiometer arm and fixed contacts for proper adjustment:
2.1. With a dry erase marker, completely coat each of the fixed contacts.
2.2. Sweep the multi-step potentiometer arm brush back and forth across the fixed contacts. Scraping of the
ink should show contact on at least 30% of the surface on each fixed contact. If 30% contact is not
shown, surface contact should be adjusted.
3. To adjust surface contact, remove the spring cotter pin (if present) (18) and turn the adjustment screw (23)
(Figure 12-13, Page 12-17) until the surfaces of the multi-step potentiometer arm brush and fixed contacts
are parallel (Figure 12-10, Page 12-14). See following NOTE .
• AFTER INSTALLING THE WIPER SWITCH, MAKE SURE IT IS SECURELY FASTENED TO THE VEHICLE FRAME.
• DO NOT OPERATE VEHICLE WITHOUT WIPER SWITCH COVER IN PLACE. OPERATING THE VEHICLE WITHOUT THE
COVER ALLOWS DIRT, DUST, AND WATER TO CONTAMINATE THE WIPER SWITCH, WHICH COULD CAUSE THE
SWITCH TO FAIL OR MALFUNCTION.
• A MID-MODEL YEAR DESIGN CHANGE RESULTED IN THE REMOVAL OF THE SPRING COTTER PIN (18) AND THE
REPLACEMENT OF THE HEX NUT (19) WITH A NYLON LOCK NUT
(FIGURE 12-13, PAGE 12-17) . USE OF A
LOCKING COMPOUND IS NOT NECESSARY IN CONJUNCTION WITH A NYLON LOCK NUT.
• IF THE MULTI-STEP POTENTIOMETER ARM BRUSH IS WORN TO OR BEYOND THE WEAR LIMIT LINE (FIGURE 12-11,
PAGE 12-14) IT SHOULD BE REPLACED. IF ANY OF THE FIXED CONTACTS ARE EXCESSIVELY WORN, PITTED, OR
BURNED, THE ENTIRE HOUSING, WITH FIXED CONTACTS, MUST BE REPLACED.
• A THREAD LOCKING COMPOUND HAS BEEN PLACED ON THE THREADS OF THE CONTACT STUDS TO PREVENT
REMOVAL OF THE FIXED CONTACTS.
WARNING
CAUTION
NOTE