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Club Car 1998 DS, Maintenance And Service Manual Supplement

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1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement

Page iii

 SECTION 10–PERIODIC MAINTENANCE

General Information  ..........................................................................................................................

10-1

Daily Pre-Operation Safety Checklist  ...............................................................................................

10-2

Periodic Service Schedule    .............................................................................................................

10-3

Lubrication ........................................................................................................................................

10-4

Vehicle Capacities  ............................................................................................................................

10-4

 SECTION 11–ELECTRICAL SYSTEM AND TESTING 

General Information  ..........................................................................................................................

11-1

Electrical Circuits  ..............................................................................................................................

11-4

The Control Circuit  .........................................................................................................................................

11-4

The Power Circuit  ..........................................................................................................................................

11-7

Electric Motor  .................................................................................................................................................

11-10

The Charge Circuit .........................................................................................................................................

11-10

Index of Test Procedures .................................................................................................................. 11-11
Diagnostic Flow Charts ..................................................................................................................... 11-11
Test Procedures  ............................................................................................................................... 11-14
The Communication Display Module (CDM)  .................................................................................... 11-22

Using The Cdm To Retrieve Data From The Onboard Computer  .................................................................

11-23

CDM Troubleshooting Guide  ............................................................................................................ 11-24

 SECTION 12–ELECTRICAL COMPONENTS  

Key Switch ........................................................................................................................................

12-2

Forward/Reverse (F&R) Rocker Switch ............................................................................................

12-3

Accelerator Pedal Limit Switch  .........................................................................................................

12-4

Reverse Buzzer  ................................................................................................................................

12-5

Main Solenoid ...................................................................................................................................

12-5

Dynamic Braking Solenoid ................................................................................................................

12-6

Onboard Computer (OBC) ................................................................................................................

12-7

Solid State Speed Controller  ............................................................................................................

12-9

Charger Receptacle Assembly  .........................................................................................................

12-9

Receptacle Fuse Link  ....................................................................................................................................

12-10

Multi-step Potentiometer ................................................................................................................... 12-11

Multi-step Potentiometer Arm Adjustment  .....................................................................................................

12-13

Multi-step Potentiometer Arm Brush Replacement ........................................................................................

12-14

Multi-step Potentiometer Adjustment  .............................................................................................................

12-15

Resistors ........................................................................................................................................................

12-15

Battery Warning Light  ....................................................................................................................... 12-16
Energy Displacement Module ........................................................................................................... 12-18
Tow/Run Switch ................................................................................................................................ 12-19

Summary of Contents for 1998 DS

Page 1: ...Manual Number 101968405 Edition Code 0299C1208B PowerDrive Plus Vehicles 1998 1999 Maintenance and Service Manual Supplement...

Page 2: ......

Page 3: ...The procedures provided herein must be properly implemented and the CAUTION WARNING and DANGER statements must be heeded This supplement was written for the vehicle technician who already possesses ba...

Page 4: ...ND DEALERS AND WILL WHEN APPLICABLE APPEAR IN FUTURE EDITIONS OF THIS MANUAL DAMAGE TO A VEHICLE OR COMPONENT THEREOF NOT RESULTING FROM A DEFECT OR WHICH OCCURS DUE TO UNREASONABLE OR UNINTENDED USE...

Page 5: ...e Communication Display Module CDM 11 22 Using The Cdm To Retrieve Data From The Onboard Computer 11 23 CDM Troubleshooting Guide 11 24 SECTION 12 ELECTRICAL COMPONENTS Key Switch 12 2 Forward Reverse...

Page 6: ...t Rotation 13 7 Numbering Vehicles and Chargers 13 7 Battery Testing 13 8 Battery Charger Test 13 8 On Charge Voltage Test 13 8 Hydrometer Test 13 8 Discharge Test 13 11 Battery Troubleshooting Exampl...

Page 7: ...Components 15 5 Armature 15 5 Field Windings 15 6 Motor Components 15 8 Bearing Inspection 15 8 Bearing Removal 15 8 Guide Ring Inspection 15 8 Reconditioning the Motor 15 9 Motor Assembly 15 10 Motor...

Page 8: ...Page vi 1998 1999 PowerDrive Plus Vehicle Maintenance and Service Supplement...

Page 9: ...HICLE 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 STATED IN THIS MA...

Page 10: ...ms Vehicle warning decals Brake system Park brake Reverse warning buzzer Steering and linkages Proper acceleration and maximum speed Batteries Accelerator Switch In addition check the items listed bel...

Page 11: ...ities Chart on Page 10 4 Multi step Potentiometer Check for cracks or other damage make sure switch is securely fastened to frame Check movable contact for correct operation General Vehicle Wash batte...

Page 12: ...elerator push rod pivots and mounts 3 Dry Moly Lube Club Car Part No 1012151 Forward Reverse Switch Contacts and charger receptacle 4 WD 40 Brake Slides 5 Dry Moly Lube Club Car Part No 1012151 Front...

Page 13: ...RGING OR USING IN AN ENCLOSED SPACE ALWAYS WEAR FULL FACE SHIELD WHEN WORKING ON OR NEAR BATTERIES USE EXTREME CAUTION WHEN USING TOOLS WIRES OR METAL OBJECTS NEAR BATTERIES A SHORT CIRCUIT AND OR SPA...

Page 14: ...ELECTRICAL SYSTEM AND TESTING General Information Page 11 2 1998 1999 PowerDrive Plus Maintenance and Service Supplement 11 Figure 11 1 Wiring Schematic Place Holder for Fold out Drawing...

Page 15: ...EEN BLUE FUSE SIX PIN CONNECTOR GREEN WHITE WHITE BLACK WHITE BLUE PURPLE YELLOW BLACK ORANGE GRN W HT WHT BL K BROW N TOW SWITCH 1 2 3 4 5 6 7 9 10 11 16 12 13 14 15 8 PIN 1 RED WIRE PIN 16 BLACK WIR...

Page 16: ...s disposed of through the energy displacement module Tow Run Switch When the Tow Run switch is in the RUN position the vehicle will function normally When the switch is in the TOW position power to th...

Page 17: ...ground speed depending on voltage input from the multi step potentiometer through the yellow black wire as the accelerator pedal is depressed 3 5 volts with pedal up zero volts with pedal fully depres...

Page 18: ...cycle 5 Locks out the motor speed controller to prevent the vehicle from moving during the charge cycle 6 Illuminates the dash warning light if there is a problem with the batteries 7 Sends a signal...

Page 19: ...page 11 22 Solid State Speed Control Circuit The Control Circuit performs the following functions 1 Monitors vehicle ground speed through the motor speed sensor 2 Regulates vehicle groundspeed by usin...

Page 20: ...E PIN 14 LIGHT GREEN WIRE PIN 12 BROWN WIRE PIN 11 BLUE WHITE WIRE PIN 10 ORANGE WIRE PIN 4 WHITE WIRE PIN 5 BLUE WIRE PIN 7 YEL BLK WIRE PIN 8 WHT BLK WIRE B B 1 2 3 CONTROLLER MULTI STEP POTENTIOMET...

Page 21: ...BLACK B L A C K RED WHITE ONBOARD COMPUTER KEY SWITCH 1 2 GREEN GREEN GREEN DASH LIGHT ORANGE WHITE SONIC WELD SONIC WELD SIX PIN CONNECTOR CONTROLLER 1 2 3 4 5 6 7 9 10 11 16 12 13 14 15 8 PIN 3 GRN...

Page 22: ...the battery pack The charge circuit supplies current from the battery charger to the batteries when the DC cord is plugged into the vehicle s charger receptacle The batteries will be discussed in Sec...

Page 23: ...e used as a reference when performing test procedures on the PowerDrive Plus vehicle More detailed system testing instructions follow MOST OF THE FOLLOWING TEST PROCEDURES ARE PERFORMED WITH THE BATTE...

Page 24: ...ST PROCEDURE 9 REPLACE MOTOR NO VOLTAGE VOLTAGE READING CORRECT VOLTAGE READING CORRECT VOLTAGE READING CORRECT OK CHECK MULTI STEP POTENTIOMETER REPAIR OR REPLACE WIRING KEY OR LIMIT SWITCH AS REQUIR...

Page 25: ...ACE DYNAMIC BRAKING SOLENOID VOLTAGE READINGS ARE CORRECT CHECK DYNAMIC BRAKING SOLENOID TEST PROCEDURE 8 NO VOLTAGE HOT COIL OK REPLACE CONTROLLER CHECK MULTI STEP POTENTIOMETER CHECK VOLTAGE AT PIN...

Page 26: ...n the OBC and the six pin connector The reading should be approximately 48 50 volts full battery voltage If the read ing is zero volts proceed to step 2 If the reading is 48 50 volts proceed to Test 3...

Page 27: ...ds before proceeding See WARNING on page 11 11 Using a multimeter set to 200 volts DC place black lead on smallpost with blue white wireand placered lead on small post with blue wire 2 Place Tow Run s...

Page 28: ...e DANGER on page 11 11 2 With Tow Run switch in RUN place Forward Reverse switch in FORWARD turn key switch ON and slowly depress accelerator pedal 3 As the accelerator pedal is depressed the voltage...

Page 29: ...8 DynamicBrakingSolenoidActivatingCoil 1 With key switch ON and Forward Reverse switch in FORWARD place Tow Run switch in RUN Using a multimeter set to 200 volts DC place the red lead on battery No 1...

Page 30: ...ading is zero volts test the continuity of the accelerator limit switch and the green white wire 4 2 If the reading is approximately 48 volts proceed to step 5 5 Place black lead of multimeter set to...

Page 31: ...g in step 1 is 48 volts plug the DC cord into the vehicle s charger receptacle The voltage reading should drop to approximately 4 0 volts before the charger relay clicks on 3 When the charger relay is...

Page 32: ...the dynamic braking solenoid does click when the key switch is turned ON or OFF the motor speed sensor may be shorted To test for this condition disconnect the motor speed sensor and attempt to drive...

Page 33: ...ng column by snapping the top out and then rotating the panel out and up 3 5 Disconnect the orange and red wires from the buzzer Make sure the wire terminals on the key switch do not touch vehicle fra...

Page 34: ...these items the item s corresponding Function Code must be selected on the CDM This is done by pressing the Function Button until the desired func tion code is displayed in the window See Figure 11 14...

Page 35: ...M Once a value has been obtained in the display window the CDM may be removed from its receiving position and the data reviewed The CDM will hold the values for F1 F2 F3 and F4 until the CDM is turned...

Page 36: ...onboard computer Contact your Club Car representative for more comprehensive information Figure 11 15 Flow Chart CDM Troubleshooting Guide Dead CDM battery Replace CDM battery Faulty CDM unit Replace...

Page 37: ...SERVICING VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES PLACE THE TOW RUN SWITCH IN THE TOW POSITION BEFORE CONNECTING OR DISCONNECTING BATTERY WIRES BEFORE PERFORMING ANY TESTS OR REPAI...

Page 38: ...cowl brace 3 4 Pull center dash out approximately one inch from the frame and then bend the top right corner of the center dash panel inward while pulling the top of the panel out and down See follow...

Page 39: ...irst and tighten to 110 in lb 12 4 N m Place Tow Run switch in RUN FORWARD REVERSE F R ROCKER SWITCH Read DANGER and WARNING on page 12 1 Testing the Forward Reverse rocker switch See Test Procedure 1...

Page 40: ...the green white and blue wires from the limit switch Accelerator Pedal Limit Switch Installation 1 Position the Accelerator Pedal Limit switch on the wiper switch body and install the mounting screws...

Page 41: ...wires from reverse buzzer 4 Remove the two screws from the reverse buzzer Remove the reverse buzzer from the center dash panel Reverse Buzzer Installation 1 Install the reverse buzzer in the reverse...

Page 42: ...late with mounting bracket 10 Figure 12 4 Page 12 5 2 Tighten thread rolling screws 11 to 20 in lb 2 2 N m Figure 12 4 Page 12 5 3 Install washers 8 wires 2 4 and 13 and lock nuts 1 onto large mountin...

Page 43: ...lb 12 4 N m Figure 12 1 Page 12 2 Place Tow Run switch in RUN ONBOARD COMPUTER OBC Read DANGER and WARNING on page 12 1 Testing the Onboard Computer See Test Procedures 2 11 and 12 Section 11 Page 11...

Page 44: ...e 7 Connect black 10 and 6 gauge wires 9 and 14 to controller B terminal Figure 12 6 Page 12 8 8 Plug the six pin connector 16 into the OBC Figure 12 6 Page 12 8 9 Install the rear body access door 10...

Page 45: ...battery cables positive cable first and tighten to 110 in lb 12 4 N m Figure 12 1 Page 12 2 Place Tow Run switch in RUN CHARGER RECEPTACLE ASSEMBLY Read DANGER and WARNING on page 12 1 Testing the Cha...

Page 46: ...e link on the PowerDrive Plus vehicle should not blow under normal operating conditions However if the fuse link has blown the vehicle will not charge and the fuse must be replaced The fuse link is mo...

Page 47: ...gure 12 13 Page 12 17 2 Remove the nut 32 and bell crank 34 Figure 12 13 Page 12 17 3 Slide the wiper arm assembly out of the housing 1 Figure 12 13 Page 12 17 4 Remove the spring cotter pin if presen...

Page 48: ...12 9 Page 12 12 2 Push locking tabs out of retainers and remove potentiometer cover 9 Figure 12 9 Page 12 12 3 Position the potentiometer on the shim plate and frame with mounting holes aligned and in...

Page 49: ...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...

Page 50: ...ckwasher 14 Pullarmassemblyawayfromfixedcontacts Figure 12 13 Page 12 17 7 2 Remove the brush by pulling the wire through the hole in the wiper arm 7 3 Install new wiper arm brush assembly 27 Figure 1...

Page 51: ...Install the 910 ohm resistor assembly 26 color bands white brown and gold onto the third and fourth threaded posts Figure 12 12 Page 12 16 See following NOTE 2 Install the 750 ohm resistor assembly 27...

Page 52: ...Protector Spray Club Car Part Number 1014305 to minimize corrosion BATTERY WARNING LIGHT Read DANGER and WARNING on page 12 1 Testing the Battery Warning Light 1 Turn key switchOFF place Tow Run swit...

Page 53: ...ance and Service Supplement Page 12 17 12 Figure 12 13 Multi step Potentiometer NOTIC E Club Car 9 30 REFERENCE ACCELERATOR ROD TYPICAL 7 PLACES 9 10 38 22 9 35 34 33 32 28 15 27 14 13 26 14 21 20 19...

Page 54: ...tallation 1 Install in reverse order of removal Reconnect battery wires positive cable first and tighten to 110 in lb 12 4 N m Place Tow Run switch in the RUN position ENERGY DISPLACEMENT MODULE Read...

Page 55: ...10 from bracket 5 Figure 12 15 Page 12 19 4 Disconnect two pin connector 11 and remove switch Figure 12 15 Page 12 19 Tow Run Switch Installation 1 Installation is reverse of removal Make sure groove...

Page 56: ...12...

Page 57: ...TACT 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 MAGNESIA OR VEGETABLE OIL CALL A P...

Page 58: ...versa The main active ele ments within a battery are the positive plates the negative plates and the electrolyte sulfuric acid Another very important element but inactive is the separator The separato...

Page 59: ...care PROBLEM MISCONCEPTION AND REALITY 1 Deep Discharge Misconception This vehicle is running slowly but we can run it until it stops Reality This statement is wrong Avoid deep discharge of batteries...

Page 60: ...not to allow this baking soda solution to enter the battery 4 Check and clean the battery rack and hold downs The nuts and bolts on the hold downs may corrode It is therefore advised that they be cle...

Page 61: ...hat they are in a full state of charge See Battery Charging Page 13 6 5 Keep hold downs tight See Vibration Damage Page 13 6 SELF DISCHARGE Dirty batteries can provide a path for a small current draw...

Page 62: ...s the capacity of the battery and cannot be replaced Battery hold downs should NOT be so tight as to crack or buckle the battery case This may cause leaks which would dry up a cell or cause internal s...

Page 63: ...es the depth of discharge and prolongs battery life EARLY EXCESSIVE DISCHARGING When vehicle batteries are new they do not reach their full capacity until they have been used and recharged 20 to 50 ti...

Page 64: ...charge voltage for the set should read between 56 0 volts and 63 0 volts depending on the age and state of charge of the batteries being tested If individual batteries read between 9 8 and 10 5 volts...

Page 65: ...s low and battery shows a variance greater than 0 4V at end of discharge Replace battery Within 0 3 volts of each other but low discharge time End of battery set useful life Replace set Battery Charge...

Page 66: ...subtract 004 from the reading Interpreting the Results of the Hydrometer Test The approximate state of charge can be determined from the following table If the difference between the cells is 020 or m...

Page 67: ...rn the tester ON 5 When the batteries have been discharging for approximately 60 minutes set the discharge machine to function 3 and checkbattery setvoltage Check voltage every 10minutesthroughout the...

Page 68: ...ime is low the batteries are approaching the end of their life and the whole set will have to be replaced In general vehicles that discharge in less than 60 minutes at 78 F on the discharge test will...

Page 69: ...ly but appears to be okay Battery No 1 should be replaced with a battery that has about the same age and usage as the other batteries Example 2 Vehicle No 70 was also suspected of having a defective b...

Page 70: ...r ON during off season storage The PowerDrive storage charge feature will automatically charge the batteries as needed throughout the storage period CHARGING BATTERY PACK WITH LOW VOLTAGE Read DANGER...

Page 71: ...See following WARNING 9 After one or two hours disconnect the charger AC cord from the electrical outlet first Then disconnect the DC cord from the charger receptacle in the vehicle 10 Disconnect the...

Page 72: ...13...

Page 73: ...E 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 INTERNAL DRINK LARGE QUANTITIE...

Page 74: ...g term storage The onboard computer will automatically activate the charger every 15 days To return the vehicle to service disconnect the DC cord from the vehicle wait 15 sec onds and then plug the DC...

Page 75: ...ecked by your Club Car distributor dealer The warning light will repeatedly illuminate for 10 seconds at 4 second intervals during a charge cycle DC plug is still connected if AC power to the charger...

Page 76: ...P THE PLUG AND PULL IT STRAIGHT OUT OF THE RECEPTACLE DO NOT PULL ON THE CORD DO NOT TWIST ROCK OR BEND THE PLUG DO NOT CONNECT THE CHARGER TO BATTERY PACKS THAT ARE NOT COMPATIBLE WITH THE DC OUTPUT...

Page 77: ...ARGER IF IT HAS RECEIVED A SHARP BLOW WAS DROPPED OR WAS OTHERWISE DAMAGED MAKE SURE IT IS OPERATING PROPERLY BEFORE PUTTING IT BACK IN USE DO NOT ALLOW CLOTHING BLANKETS OR OTHER MATERIALS TO COVER T...

Page 78: ...rom the vehicle charger receptacle insert the AC cord into an outlet The charger relay should NOT close A multimeter set to volts DC and connected across the DC plug positive and negative pins should...

Page 79: ...le Normal voltage toward the end of a charge cycle should be approximately 59 to 63 volts while the charger is still operating START CHARGE CYCLE 1 Disconnect the DC plug from the vehicle s charger re...

Page 80: ...The flow charts on pages 14 10 through 14 12 refers specifically to the onboard computer and battery charger Test proce dures specified in these charts can be found on the pages immediately following...

Page 81: ...ocedure 8 Page 14 17 3 Relay closes and transformer hums but ammeter does not move 1 Blown charger fuse Test Procedure 4 Page 14 14 2 Both diodes failed Test Procedure 4B Page 14 15 3 Onboard computer...

Page 82: ...C power interrupted Test Procedure 3 Page 14 14 2 Onboard computer malfunction Test Procedure 2 Page 14 13 3 Charger failure See page 14 7 4 16 hour time out See page 14 3 5 Battery or batteries need...

Page 83: ...N POWER DOWN MODE DISCONNECT CHARGER DC PLUG AND DRIVE VEHICLE FOR A FEW MINUTES RECONNECT CHARGER PLUG DOES CHARGER ACTIVATE OBC PROGRAM MAY BE LOCKED UP REMOVE DC CORD FROM RECEPTACLE REBOOT COMPUTE...

Page 84: ...receptacle for damage dirt corrosion or any condition that might prevent a good electrical connection 2 Inspect the receptacle contacts to ensure that they are not damaged and they are firmly seated w...

Page 85: ...o allow the onboard computer to close the charger relay If battery pack voltage is too low to start charger see Section 13 Batteries Charging Battery Pack With Low Voltage Test Procedure 2 Onboard Com...

Page 86: ...former primary coil leads internal AC cir cuit breaker and jumper wire Figure 14 16 Page 14 17 7 If the charger is wired correctly check the continuity of the AC cord transformer primary coil and the...

Page 87: ...rmer will hum but the ammeter will not indicate any output If both diodes have failed open or closed the entire heat sink assembly must be replaced To determine why both diodes failed 1 Check the batt...

Page 88: ...transformer may be caused by aging or a short circuit in adjacent coil turns If the transformer has failed the ammeter would indicate low output or no output however transformer may hum A blown AC li...

Page 89: ...a full charge and the onboard computer should be checked See Test Procedure 2 Test Procedure 8 Continuity AC Cord and Plug Check continuity of the AC cord Figure 14 17 Page 14 18 1 Disconnect the AC...

Page 90: ...let and the DC plug from the receptacle then remove the charger cover 2 To check the continuity of the DC cord disconnect the black wire of the DC cord from the ammeter Figure 14 18 Page 14 20 3 Disco...

Page 91: ...inal of the heat sink assem bly and place the tester clip on the ammeter bus bar 7 Figure 14 16 Page 14 17 Place the continuity leads on each tan secondary coil lead Tester should register continuity...

Page 92: ...D 40 brand spray lubricant See Section 12 Page 14 9 for charger receptacle replacement CHARGER CORD AND PLUG REPLACEMENT Charger Cord and Plug Removal 1 Disconnect the AC and DC plugs See preceding WA...

Page 93: ...EAT SINK ASSEMBLY Heat Sink Assembly Removal 1 Remove charger cover See preceding WARNING 2 Remove both secondary transformer leads tan from the heat sink assembly Figures 14 4 and 14 5 Pages 14 7 and...

Page 94: ...sink assembly Figures 14 4 and 14 5 Pages 14 7 and 14 8 Tighten nut to 18 in lb 2 0 N m 4 Connect one secondary transformer lead black to one terminal of the fuse assembly Figures 14 4 and 14 5 Pages...

Page 95: ...wed from the front of the charger 2 Install the bus bar over the center branch of the fuse assembly and ammeter post Figure 14 20 Page 14 23 Tighten to 27 in lb 3 0 N m 3 Install a secondary transform...

Page 96: ...Removal 1 Disconnect the AC and DC cords See WARNING on page 14 21 2 Remove the charger cover 3 Disconnect the red blue black and primary coil wires from the relay Figure 14 21 Page 14 24 4 Remove the...

Page 97: ...al 1 Disconnect the AC and DC cords See WARNING on page 14 20 2 Remove the charger cover 3 Disconnect the AC cord black wire at the circuit breaker Figure 14 21 Page 14 24 4 Disconnect the AC cord whi...

Page 98: ...14...

Page 99: ...WATER FOR FIFTEEN MINUTES CALL PHYSICIAN IMMEDIATELY ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN...

Page 100: ...n A1 A2 F1 and F2 terminals respectively Figure 15 1 Page 15 2 Multimeter should indicate no continuity If readings are incorrect motor will need to be removed from the vehicle and repaired by a quali...

Page 101: ...If the reading is incorrect a possi ble open field coil or bad connections at the terminals may be the cause The motor will need to be removed from the vehicle and repaired by a qualified technician...

Page 102: ...with wooden blocks as shown Figure 15 5 Page 15 5 2 Remove the four bolts 8 securing the end shield 10 to the stator shell 2 Figure 15 5 Page 15 5 3 Remove the two screws 9 attaching the end shield t...

Page 103: ...h Thrown solder Flared armature windings Damaged armature core laminations Worn burned or glazed commutators Dirty or oily commutators Raised commutator bars Worn armature bearing or shaft A dirty or...

Page 104: ...ted due to overloads or grounded or shorted coil windings If the insulation on the field windings is scorched replace the motor or the sta tor shell assembly NEVER USE EMERY CLOTH TO SMOOTH THE COMMUT...

Page 105: ...1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 15 7 15 Figure 15 8 Motor 29 22 23 24 21 28 27 1 2 16 15 7 14 13 12 17 20 18 8 TYPICAL 4 PLACES 9 TYPICAL 2 PLACES TYPICAL 2 PLACES...

Page 106: ...tachment tool Club Car Part No 1012812 between the bearing 15 and the armature Figures 15 8 and 15 12 Pages 15 7 and 15 11 Make sure the wedge attachment tool is supporting the inner race of the beari...

Page 107: ...813201 then slide the guide ring onto the guide ring installation tool Figure 15 11 Page 15 9 next to the guide ring already in place Mating the splines of the input shaft with the splines in the arma...

Page 108: ...Figure 15 6 Page 15 5 5 Slide the armature bearing end first into the stator shell Make sure the brushes are held back while positioning the armature for proper commutator brush contact Release the b...

Page 109: ...g Removal Figure 15 13 Guide Ring Removal IF THE MOTOR IS BEING ASSEMBLED WITH THE ARMATURE STANDING ON END AS THE COMMUTATOR IS POSITIONED MAKE SURE THE BRUSHES ARE HELD BACK DO NOT ALLOW THE BRUSHES...

Page 110: ...s to 65 in lb 7 3 N m Tighten the 5 16 in bolt D to 155 in lb 17 5 N m Figure 15 17 Page 15 13 6 Install the motor wires Make sure they are connected to the correct terminals Tighten the terminal reta...

Page 111: ...igure 15 14 Brush Installation Figure 15 15 End Shield Installation Figure 15 16 Motor Installation Figure 15 17 Motor Mount MOUNTING TAB F 1 A 1 F 2 A2 RIGGING TERMINAL POST BEARING RETAINER END SHIE...

Page 112: ...eed Sensor Installation 1 Position the motor speed sensor 21 in the recessed area on the motor Sensor should fit flush against the motor Figure 15 18 Page 15 14 2 Position retaining plate 23 over moto...

Page 113: ...EED ALL WARNINGS STATED IN THIS MANUAL WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE TURN KEY SWITCH OFF PLACE FORWARD REVERSE ROCKER SWITCH IN THE NEUTRAL POSITION AND REMOVE...

Page 114: ...the lubricant When draining the lubricant the upper plug should be removed so the lubricant will drain faster Be sure the drain plug is reinstalled before refilling AXLE SHAFT AND BEARING Read DANGER...

Page 115: ...he axle shaft 7 Inspect bearing 5 Figure 16 4 Page 16 4 or Figure 16 5 Page 16 5 If the bearing in a Type K transaxle is worn or damaged replace bearing If the bearing in a Type G transaxle is worn or...

Page 116: ...s Maintenance and Service Supplement 16 Figure 16 4 Transaxle Type K 13 12 37 34 36 37 34 33 31 30 29 28 27 41 24 26 6 5 17 4 7 40 2 3 8 9 15 20 21 23 18 18 18 19 1 3 8 9 10 11 42 43 14 15 4 16 7 17 5...

Page 117: ...s Vehicle Maintenance and Service Supplement Page 16 5 16 Figure 16 5 Transaxle Type G 12 25 20 6 5 15 4 7 35 2 3 8 9 18 19 16 16 16 17 1 3 8 9 10 11 37 38 4 14 7 15 5 6 21 23 22 13 REFERENCE MOTOR SE...

Page 118: ...bearing 5 and collar 4 off together Figure 16 6 Page 16 6 DO NOT REMOVE AXLE BEARING FROM A TYPE G TRANSAXLE IF BEARING IS WORN OR DAMAGED THE ENTIRE AXLE ASSEMBLY 1 OR 2 MUST BE REPLACED FIGURE 16 5...

Page 119: ...hrough the seal and into the axle tube Be careful not to damage the seal Then advance the shaft through the inner bearing and rotate it to align the shaft splines with the splined bore of the differen...

Page 120: ...lug nut onto stud on each rear hub This will keep brake drums on hubs 4 Remove the cotter pins 1 brake cable clevis pins 2 and cable retaining E clips 3 Disconnect the brake cables 4 Figure 16 9 Page...

Page 121: ...WARNING 11 If a floorjack was used pull floorjack from beneath the transaxle and allow the springs to rest on the floor 12 Remove the U bolts attaching the transaxle to the leaf springs Figure 16 12...

Page 122: ...e 16 5 by pulling gear out while rocking intermediate gear assembly Lift intermediate gear assembly and differential gear case unit out simultaneously 5 Use a bearing puller or arbor press to remove b...

Page 123: ...ge 16 4 or four hex bolts 33 Figure 16 5 Page 16 5 that secure the ring gear to the differential case 9 3 Remove the ring gear Retain dowel pin from between the ring gear and differential case for rea...

Page 124: ...bolts to 18 ft lb 24 N m 2 4 Bend the edges of the bolt locking tabs securely against the flats of the bolt heads to prevent the bolts from loosening and possibly causing damage Figure 16 17 Page 16...

Page 125: ...axle housing 20 Figure 16 5 Page 16 5 8 7 Install eleven bolts in the case housing and tighten to 19 ft lb 25 7 N m Type G transaxles have no shims or gasket 8 8 Install axle tube with lock washers an...

Page 126: ...ge 16 14 3 Use the following chart to determine whether shimming is required and if so how many shims Club Car Part No 1013781 should be used TRANSAXLE INSTALLATION Read DANGER and WARNING on page 16...

Page 127: ...wo wrenches to pre vent the motor studs from turning See following NOTE 7 Insert bolts through the spring shackles and bushings in the leaf spring eyes Secure bolts with lock nuts Tighten to 15 ft lb...

Page 128: ...16...

Page 129: ...Club Car R NOTES...

Page 130: ...Club Car R NOTES...

Page 131: ......

Page 132: ...Club Car Inc P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Int l 1 706 863 3000 Fax 1 706 863 5808...

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