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Club Car TransPorter 4, Maintenance And Service Manual

Introducing the Club Car TransPorter 4 Maintenance and Service Manual, your ultimate guide to ensure optimal performance and longevity of your vehicle. This comprehensive manual covers all aspects of maintenance, providing step-by-step instructions for hassle-free upkeep. Download this invaluable resource for free today from manualshive.com to unlock the full potential of your Club Car TransPorter 4.

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SECTION 5 — ACCELERATOR AND BRAKE PEDAL GROUP

5

Accelerator and Brake Pedal Group

DANGER

• See General Warnings on page 1-2.

WARNING

• See General Warnings on page 1-2.

BRAKE PEDAL AND PARK BRAKE

See General Warnings on page 1-2.

BRAKE PEDAL REMOVAL

1.

Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire(s).

See

Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-3.

Place chocks under the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack. Place
jack stands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands.

See

following WARNING.

WARNING

• Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic floor

jack) with 1000 lb (454 kg) minimum lifting capacity. Do not use lifting device to hold vehicle in raised
position. Use approved jack stands of proper weight capacity to support the vehicle and chock
the wheels that remain on the floor. When not performing a test or service procedure that requires
movement of the wheels, lock the brakes.

2.

Remove the brake pedal assembly.

2.1.

Disconnect the equalizer rod (5) from the pedal shaft by removing the clevis pin (7) and bow-tie pin (4)

(Figure 5-1, Page 5-2)

.

2.2.

Remove the nuts (2), flat washers (10), bolts (11), and mounting blocks (3 and 8). If the mounting blocks

(3 and 8) show signs of excessive wear or are damaged, they must be replaced with new ones before
installing pedal assembly.

2.3.

Remove the nut (12) and brake stop bumper (13) and lift pedal assembly (1) through the floorboard

(Figure

5-2, Page 5-3)

.

2019 Transporter Maintenance and Service Manual

Page 5-1

Summary of Contents for TransPorter 4

Page 1: ...2019 Transporter Maintenance and Service Manual Electric Vehicle with QuiQ Charger Manual Number 105355114 Edition Code B ...

Page 2: ......

Page 3: ...onal technical representatives vehicle service seminars periodic service bulletins maintenance and service manuals and other service publications also represent Club Car s continuing commitment to customer support Club Car offers a full line of training and continuing education classes for technicians who want to learn more about our products For more information contact your local dealer or Club ...

Page 4: ...cle read complete section s and any referenced information that may be relevant to the service or repair to be performed NOTE This manual represents the most current information at the time of publication Club Car is continually working to further improve its vehicles and other products These improvements may affect servicing procedures Any modification and or significant change in specifications ...

Page 5: ... Front Body Repair 4 2 Light Scratches 4 2 Abrasions and Haze 4 2 Large Scratches and Abrasions 4 2 Front Body 4 2 Brushguard Removal 4 2 Brushguard Installation 4 3 Cowl Removal 4 4 Cowl Installation 4 4 Grille Removal 4 6 Grille Installation 4 6 Front Bumper and Side Fender Removal 4 8 Front Bumper and Side Fender Installation 4 8 Instrument Panel Removal 4 9 Instrument Panel Installation 4 9 Da...

Page 6: ...ment 6 7 Brake Cluster Adjustment 6 8 Brake Cable Equalization 6 10 Final Brake Cluster Adjustment 6 11 Test Drive Vehicle 6 11 Brake Cluster Removal and Installation 6 12 Front Brake Cluster Removal 6 12 Front Brake Cluster Installation 6 12 Rear Brake Cluster Removal 6 14 Rear Brake Cluster Installation 6 14 Front Brake Cables 6 15 Front Brake Cable Removal 6 16 Front Brake Cable Installation 6 ...

Page 7: ... Bearings Installation 7 22 SECTION 8 Wheels and Tires 8 1 General Information 8 1 Wheels 8 1 Wheel Removal 8 1 Wheel Installation 8 1 Tires 8 2 Tire Removal 8 2 Tire Repair 8 2 Tire Installation 8 3 SECTION 9 Rear Suspension 9 1 General Information 9 1 Shock Absorbers 9 1 Shock Absorber Inspection and Removal 9 1 Shock Absorber Installation 9 1 Multi Leaf Springs 9 2 Multi Leaf Spring Removal 9 2...

Page 8: ...Main Cont 11 12 Password Tries OEM Access Level Only 11 12 Cir BRKR Open 11 13 THRTL Fault 11 13 Undervoltage 11 13 Overvoltage 11 13 Temp Cutback 11 13 HPD 11 13 Main Welded 11 13 Relay Welded 11 13 SPD Sensor 11 13 Main DRV On 11 13 Main Coil OPN 11 13 Main Dropout 11 13 Motor Stall 11 13 Main DRVR Off 11 13 Relay DNC 11 14 Current Sense 11 14 M Shorted 11 14 Relay Coil 11 14 Precharge 11 14 FLD...

Page 9: ...1 21 24 HW Failsafe 11 21 25 Incorrect Password 11 22 26 Circuit BRKR Open 11 22 27 Max Password Tries 11 22 29 Relay DRVR Off 11 22 30 Relay Coil Fault 11 22 Anti Tamper Fault 11 22 Lockout Fault 11 22 Low SOC 11 22 Main CONT DNC 11 23 Main Coil Fault 11 23 PROC Wiring 11 23 Open Armature 11 23 Incorrect Password OEM Access Level Only 11 23 Fault History 11 23 Clearing Fault History 11 23 Program...

Page 10: ...Solenoid Removal 13 7 Solenoid Installation 13 7 Speed Controller 13 8 Speed Controller Removal 13 8 Speed Controller Installation 13 8 Charge Indicator Light 13 10 Testing the Charge Indicator Light 13 10 Charge Indicator Light Removal 13 10 Charge Indicator Light Installation 13 10 Emergency Stop Switch 13 10 Testing the Emergency Stop Switch 13 10 Emergency Stop Switch Removal 13 10 Emergency S...

Page 11: ... Protection Rating 15 1 How To Identify Charge Algorithm Number 15 2 How To Change The Algorithm 15 3 The Charge Circuit 15 3 Onboard Charger Operation 15 4 Charger Displays 15 6 AC Power Connection 15 8 Charging Batteries 15 8 Maintenance 15 9 Troubleshooting 15 10 Test Procedures 15 11 Charger Repairs 15 12 Onboard Charger Removal And Installation 15 12 Onboard Charger Removal 15 12 Onboard Char...

Page 12: ...le Disassembly Inspection and Assembly 17 8 Transaxle Disassembly and Inspection 17 8 Transaxle Assembly 17 10 Transaxle Installation 17 11 SECTION 18 Wiring Diagrams 18 1 General Information 18 1 Index Index 1 Page x 2019 Transporter Maintenance and Service Manual ...

Page 13: ...ed with Danger is RED WARNING A WARNING indicates an immediate hazard that could result in severe personal injury or death The color associated with Warning is ORANGE CAUTION A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result in minor personal injury The color associated with Caution is YELLOW MACHINE SAFETY CAUTION A CAUTION without the safety alert sym...

Page 14: ...hicle or increases maximum vehicle speed beyond factory specifications can result in severe personal injury or death Check the vehicle for proper location of all vehicle safety and operation decals and make sure they are in place and are easy to read For vehicles with cargo beds remove all cargo including accessories before raising the bed or servicing the vehicle If the vehicle is equipped with a...

Page 15: ...hock the wheels if servicing or repairing the vehicle DISCONNECTING THE BATTERIES ELECTRIC VEHICLES 1 Disable the vehicle See Disabling the Vehicle on page 1 3 2 Place Run Tow switch in the TOW position before disconnecting or connecting the batteries Failure to heed this warning can result in a battery explosion or severe personal injury 3 Disconnect the batteries negative cable first as shown Fi...

Page 16: ... contaminate both water and soil causing environmental damage and personal injury Lead acid batteries are identified by the symbol shown below and should be properly recycled Figure 1 2 They cannot be disposed as municipal waste and must be collected separately Responsibility for environmental protection must be shared not only by the manufacturers of the batteries but by people who use the batter...

Page 17: ...n the vehicle battery or batteries _ 1 Shield eyes 3 No smoking no open flames no sparks 5 Battery acid hazard 2 Read and follow operating instructions 4 Keep away from children 6 Explosive gas hazard Refer to General Warnings for more information 1642 Figure 1 3 International Safety Symbols on Batteries 2019 Transporter Maintenance and Service Manual Page 1 5 ...

Page 18: ...Pagination Page 1 General Warnings SAFETY Page 1 6 2019 Transporter Maintenance and Service Manual ...

Page 19: ...ame chassis Twin I Beam welded aluminum Side and rear body All aluminum Front body ArmorFlex Front body finish Automotive grade paint with clear coat finish Tires 20 x 10 10 tubeless 6 ply rated load range front and rear DIMENSIONS WEIGHT Overall length Standard rear cover with rear seat Add 1 8 in 4 5 cm for heavy duty front bumper 140 6 in 357 2 cm 146 9 in 373 0 cm Overall width Without mirrors...

Page 20: ...ted capacity With boxbed Level surface only 1300 lb 590 kg Standard seating capacity 4 LIQUID CAPACITIES Transaxle 22 fl oz 0 67 L TIRE PRESSURE Front and rear 28 to 32 psig 193 to 221 kPa NOISE AND VIBRATION Transporter Electric with Stakeside Kit or Rear Seat Drive by noise level to operator Test method EN 12053 2001 72 dBa Uncertainty 2 dBa Transporter Electric with Stakeside Kit or Rear Seat V...

Page 21: ...C POWER CONSUMPTION AC current amps Max 12 Amps Nominal 9 5 Amps rms 120 VAC 5 Amps rms 230 VAC DC OUTPUT DC voltage VDC nominal 48 V DC voltage VDC maximum 68 V DC current maximum 18 Amps Interlock current maximum 1 Amp DIMENSIONS WEIGHT Case Overall length 11 in 28 cm Case Overall width 9 7 in 24 6 cm Case Overall height 4 3 in 11 cm Weight with standard output cord 11 lb 5 kg MOUNTING CONFIGURA...

Page 22: ...Pagination Page 2 Vehicle Specifications VEHICLE SPECIFICATIONS Page 2 4 2019 Transporter Maintenance and Service Manual ...

Page 23: ...number of each vehicle is printed on a bar code decal mounted below the center dash panel Example CC5819 123456 Figure 3 1 The two letters 1 at the beginning of the serial number indicate the vehicle model The following four digits 2 indicate the model year and production week during which the vehicle was built The six digits 3 following the hyphen represent the unique sequential number assigned t...

Page 24: ...s To avoid exposing electrical components to moisture and subsequent damage do not use any type or pressure washing or steam cleaning equipment to wash the vehicle PREPARING THE VEHICLE FOR EXTENDED STORAGE Check Battery Water Levels Two Weeks Prior to Storage Check water levels at least two weeks prior to winter storage to ensure proper mixing of water and electrolyte Note that it takes approxima...

Page 25: ...NOTE It is recommended that the vehicles be plugged in and the electrolyte level maintained throughout the storage period If any of the following conditions exist however then disconnect the batteries for storage 1 The charger cannot remain plugged in 2 AC power will not be available during extended storage or 3 Electrolyte levels will not be maintained To disconnect batteries for storage go to st...

Page 26: ...Pagination Page 3 Storing the vehicle GENERAL INFORMATION Page 3 4 2019 Transporter Maintenance and Service Manual ...

Page 27: ...omotive cleaning solutions with a sponge or soft cloth The painted finish is the same paint used in automotive applications Automotive cleaning polishing products are available at automotive specialty and hardware stores Use non abrasive wax products Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately to prevent possible stains SEAT CLEANING Clean seat...

Page 28: ...buffing compound as necessary to achieve this step If at any time original scratches can be seen repeat steps 2 and 3 as needed When all 1500 grit scratches have disappeared there will be a dull luster over entire area 5 Install a foam polishing pad 3M 5725 or equivalent on buffer and repeat step 4 using approx 1 2 tsp 2 mL buffing compound 3M 5933 or equivalent Buff compound off until scratches h...

Page 29: ... 1 Position the brushguard 4 onto the vehicle Figure 4 1 Page 4 3 2 Install the washers 3 screws 2 and bolts 1 Tighten the bolts to 36 ft lb 49 N m Tighten the screws to 25 ft lb 34 N m 3 Connect the batteries See Connecting the Batteries Electric Vehicles Section 1 Page 1 4 Figure 4 1 Brushguard 2019 Transporter Maintenance and Service Manual Page 4 3 ...

Page 30: ... three tabs on cowl install under lip of dash 1 Figure 4 2 Page 4 5 3 Ensure sides of cowl 3 assemble between the two ribs on side of dash 4 Ensure center tab on cowl assembles beneath the rib in the grille 5 With fenders disengaged from the front bumper press down on front fenders line up cowl tabs and fully engage snap tabs 6 Ensure front corners of cowl are engaged with front fender 2 7 Engage ...

Page 31: ...BODY AND TRIM Front Body 4 34 35 36 36 37 2846 Figure 4 2 Front Cowl 2019 Transporter Maintenance and Service Manual Page 4 5 ...

Page 32: ...e charger receptacle if equipped by removing the three screws that attach the receptacle or disconnect connector quick connect GRILLE INSTALLATION 1 Connect the charger receptacle or connector quick connect 2 Install but do not tighten upper M6 screws Do not tighten screws until plastic bumper is installed 3 Lower grille holes are shared with the front bumper ensure lower bumper screws are attache...

Page 33: ...BODY AND TRIM Front Body 4 6 7 2 3 4 5 6 9 8 1 1 2844 Figure 4 3 Front Grille Bumper and Side Fenders 2019 Transporter Maintenance and Service Manual Page 4 7 ...

Page 34: ...e fender to the frame repeat procedure on opposite side 9 Unsnap body clips and remove side fenders 5 FRONT BUMPER AND SIDE FENDER INSTALLATION 1 Install side fenders 5 by snapping in body clips 2 Install inner screws nuts and spacers 1 2 3 and 4 that attach the side fender to the frame 3 Install front bumper 6 4 Install the two upper and lower bolts 7 that attach the bumper to the vehicle frame P...

Page 35: ...pop out the lower body clips be careful not to pry the lower clips off 4 Pull instrument panel out from the dash panel 2 INSTRUMENT PANEL INSTALLATION 1 Place upper tab of instrument panel into slot 1 2 Snap panel into dash while pushing in on the driver and passenger side tabs and sliding the top portion of the panel into place 3 Snap lower body clips in at each lower corner 4 Connect the batteri...

Page 36: ...top sides and bottom of the dash 10 Figure 4 5 Page 4 11 6 Remove dash assembly DASH INSTALLATION 1 Install dash assembly 2 Install the bolts and washers 5 6 7 8 and 9 to the top sides and bottom of dash 10 Figure 4 5 Page 4 11 3 Connect instrument panel wiring 4 Install steering wheel See Steering Wheel Installation Section 7 Page 7 2 5 Install cowl See Cowl Installation Section 4 Page 4 4 6 Conn...

Page 37: ...BODY AND TRIM Front Body 4 10 6 7 8 9 4 5 2863 Figure 4 5 Dash Assembly 2019 Transporter Maintenance and Service Manual Page 4 11 ...

Page 38: ... Page 4 13 2 Remove two lock nuts 8 from left and right hinge assemblies C 3 Apply slight upward pressure by hand on the rear of the bed to relieve pressure on the hinges and remove the hinge bolts 7 from the hinge assemblies 4 Raise rear edge of bed approximately 6 inches 15 2 cm and pull bed assembly toward rear of vehicle approximately 3 inches 7 6 cm to release bed latch assembly A from latch ...

Page 39: ...BODY AND TRIM Tilt Bed 4 14 6 1 12 10 1 13 7 8 17 11 2 9 18 16 3 15 5 4 19 9 A B C 2980 Figure 4 6 Tilt Bed Mounting 2019 Transporter Maintenance and Service Manual Page 4 13 ...

Page 40: ...hands clear of all crush areas Do not drop cargo bed lower gently and keep entire body clear Failure to heed this warning could result in severe personal injury or death 4 Remove the four bolts 12 and lock nuts 7 that secure the bed latch 6 to the underside of the bed Figure 4 7 Page 4 15 5 Remove the bed latch 6 and springs 5 BED LATCH ASSEMBLY INSTALLATION 1 Install bed latch 6 and springs 5 NOT...

Page 41: ...BODY AND TRIM Tilt Bed 4 2 13 9 8 11 11 7 7 12 8 4 3 10 6 5 1 2982 Figure 4 7 Bed Latch Assembly 2019 Transporter Maintenance and Service Manual Page 4 15 ...

Page 42: ...r Fenders and Tailskirt BODY AND TRIM REAR FENDERS AND TAILSKIRT See General Warnings on page 1 2 4 3 2 1 5 2984 Figure 4 8 Rear Fender and Tailskirt Page 4 16 2019 Transporter Maintenance and Service Manual ...

Page 43: ...ng a 10 mm socket remove the two M6 screws 2 that attach the tailskirt 3 to the vehicle frame 7 Remove fenders and tailskirt REAR FENDER AND TAILSKIRT INSTALLATION 1 Using a 10 mm socket install the two screws 2 that attach the tailskirt 3 to the vehicle frame Figure 4 8 Page 4 16 Tighten to 44 in lb 5 N m 2 Using a 10 mm socket install the three fasteners 5 that attach the rear fender 4 to the ve...

Page 44: ...rtically align the lower edge of the triangle plate with the lower part of the flat vertical surface 1 2 Use the four holes in the triangle plate as a template Match drill four 0 20 inch 5 08 mm holes through the tail skirt Deburr all holes drilled and remove unwanted material 2 Attach the triangle plate to the tail skirt with four washers 3 and four new rivets 4 3 Make sure that the air and surfa...

Page 45: ...yl Alcohol prep pad 70 percent Isopropyl Alcohol and 30 percent water Wipe dry before the Isopropyl Alcohol dries 7 Install the reflective triangle decal 5 on the triangle plate Make sure to keep proper alignment and remove any air bubbles 2019 Transporter Maintenance and Service Manual Page 4 19 ...

Page 46: ...4 Electric Bed Lift BODY AND TRIM ELECTRIC BED LIFT 7 14 2 5 9 3 13 12 11 4 5 14 2 1 4 7 7 2983 Figure 4 10 Electric Bed Lift Page 4 20 2019 Transporter Maintenance and Service Manual ...

Page 47: ...ures lift 7 Figure 4 10 Page 4 20 5 Lower the bed 6 Remove the hex head bolts lock nuts spacers and bushings 1 2 5 6 7 and 8 Figure 4 11 Page 4 22 ELECTRIC BED LIFT INSTALLATION 1 Install hex head bolts lock nuts spacers and bushings 1 2 5 6 7 and 8 Figure 4 11 Page 4 22 2 Lift bed 3 Install actuator hardware that secures lift 7 Figure 4 10 Page 4 20 4 Connect actuator wires 5 Lower bed 6 Connect ...

Page 48: ...Page 5 1 2 Remove the top edge of the floor mat from the overlapping flange under the dash 3 Lift the mat from the vehicle FLOOR MAT INSTALLATION 1 Install mat into vehicle Ensure mat is laying flat 2 Install top edge of the floor mat into the overlapping flange under the dash 3 Install the brake and accelerator pedals See Accelerator and Brake Pedal Group Section 5 Page 5 1 Page 4 22 2019 Transpo...

Page 49: ...BODY AND TRIM Rear Facing Seat 4 REAR FACING SEAT 3214 Figure 4 12 Rear Facing Seat Frame 2019 Transporter Maintenance and Service Manual Page 4 23 ...

Page 50: ...the hitch is mounted to frame remove two nuts lockwashers flat washers and bolts 3 Where the hitch is mounted to hitch brace remove the nut lockwasher flat washer and bolt 4 Remove hitch from vehicle TRAILER HITCH INSTALLATION 1 Mount hitch to hitch brace install nut lockwasher flat washer and bolt 2 Install hitch to frame install two nuts lockwashers flat washer and bolts Page 4 24 2019 Transport...

Page 51: ...d Causes severe 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 magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately WARNING Wear safety glasses or approved eye protection when servicing the vehicle ...

Page 52: ...26 4 Remove the two self threading screws 1 from passenger side of electrolyte tray 2 or 3 using a 3 8 inch socket 5 Remove electrolyte tray 2 or 3 from underneath vehicle ELECTROLYTE TRAY INSTALLATION 1 Place electrolyte tray 2 or 3 underneath vehicle Figure 4 14 Page 4 26 2 Lift driver side of electrolyte tray 2 or 3 to chassis and align screw holes 3 Install two self threading screws 1 into hol...

Page 53: ...ing device chain hoist or hydraulic floor jack with 1000 lb 454 kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 2 Remove the brake pedal a...

Page 54: ... install the brake pedal stop bumper 13 Figure 5 1 Page 5 2 on the brake pedal assembly but do not tighten the jam nut 12 at this time 2 Secure the equalizer rod 5 to the brake pedal assembly 1 with clevis pin 7 and bow tie pin 4 as shown Transporter Electric Vehicle shown Transporter Gas Vehicle similar 3208 Figure 5 1 Brake and Park Brake Pedal Assembly and Mounting Page 5 2 2019 Transporter Mai...

Page 55: ...age 5 3 See following NOTE NOTE Brake pedal free play is the distance the brake pedal can be pressed before the brake actuator arm moves 5 Tighten the jam nut 3 while holding the adjustment nut 2 in the correct position 6 Adjust the pedal group Refer to the appropriate adjustment procedure For gasoline vehicles see For electric vehicles see Pedal Group Adjustment Electric Vehicles on page 5 8 A 1 ...

Page 56: ... the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 3 Remove the park brake assembly 3 1 To remove the park brake rod and pawl assembly 17 through 20 remove the push nut 19 and disconnect the ball joint sleeve 21 from the park brake pedal 1 Figure 5 4 Page 5 4 See following NOTE NOTE New push nuts 19 and 32 must ...

Page 57: ... assembly 4 Install the two bushings 30 in the park brake pedal and position the park brake pedal on the shaft on the brake pedal assembly weldment 10 Then attach the ends of the torsion spring to the park brake pedal and to the brake pedal weldment as shown Figure 5 5 Page 5 4 5 Install the push nut 32 on the park brake pedal shaft Figure 5 4 Page 5 4 6 Connect park brake rod 17 with ball joint 2...

Page 58: ...RAKE PEDAL GROUP ACCELERATOR PEDAL ELECTRIC VEHICLES See General Warnings on page 1 2 GO 3 2 11 10 7 5 4 5 1 8 9 6 15 16 21 20 21 22 24 23 2642 Figure 5 6 Accelerator Pedal Electric Vehicle with MCOR Page 5 6 2019 Transporter Maintenance and Service Manual ...

Page 59: ...wing NOTE NOTE Failure to mark position of the ratchet could cause it to be installed improperly resulting in improper adjustment and possible failure of the park brake 9 Remove the lock nut 23 from the accelerator pivot rod 10 Press the brake pedal slightly and slide the park brake ratchet 24 toward the end of the accelerator pivot rod Rotate the ratchet and remove it from the pivot rod 11 Remove...

Page 60: ...to align the splines 10 Install lock nut 23 on pivot rod Figure 5 6 Page 5 6 Tighten to 18 ft lb 24 5 N m 11 Install the MCOR 2 and drive bar 3 as instructed See MCOR Installation Section 13 Page 13 5 12 Adjust the accelerator pedal height See Pedal Group Adjustment Electric Vehicles on page 5 8 PEDAL GROUP ADJUSTMENT ELECTRIC VEHICLES See General Warnings on page 1 2 1 Disconnect the batteries an...

Page 61: ... Figure 5 9 Page 5 9 3 2 Tighten the nut 2 on the equalizer rod 1 so that the brake pedal free play is 1 4 inch to 1 2 inch 6 3 mm to 12 7 mm Figure 5 3 Page 5 3 3 3 Tighten the jam nut 3 while holding the adjustment nut 2 in the correct position 4 Adjust park brake ratchet pawl gap and pawl engagement 4 1 Inspect the park brake pawl 1 and ratchet 2 for excessive wear grooves cracks or chips Figur...

Page 62: ...ure 5 11 Accelerator Pedal Height Measurement Figure 5 12 Ratchet Pawl Tooth Engagement 4 5 With park brake still locked measure the distance from the top of accelerator pedal to floorboard If the measurement has changed ratchet tooth engagement is too deep and must be adjusted 4 6 If ratchet pawl engagement must be adjusted disconnect the ball joint at the top of the brake rod and rotate the ball...

Page 63: ...b 35 3 N m Figure 5 15 Page 5 11 1 2 1 1 2 Inch Socket 2 1 2 Inch Wrench Figure 5 13 Brake Rod Adjustment Figure 5 14 Accelerator Pedal Height Adjustment STOP PARK GO GO STOP PARK MICRO BREAK POINT MICRO BREAK POINT 1 2 1 Accelerator Pedal Adjustment Tool 2 Rubber Strap Figure 5 15 Accelerator Pedal Height Adjustment 6 Adjust the brakes See Brake Adjustment Section 6 Page 6 7 7 Connect the battery...

Page 64: ...Pagination Page 5 Pedal Group Adjustment Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP Page 5 12 2019 Transporter Maintenance and Service Manual ...

Page 65: ...operated pedal actuated hand operated lever actuated BRAKE SHOE REMOVAL See General Warnings on page 1 2 See also Asbestos Dust Warning on page 6 1 1 To remove rear brake shoes place chocks at the front wheels loosen the rear wheel lug nuts and lift the rear of the vehicle with a chain hoist or floor jack Place jack stands under the axle tubes to support the vehicle 2 Release park brake if latched...

Page 66: ...leting step 6 skip step 7 See following NOTE NOTE Although step 6 allows easier access to the brake shoes it is not imperative to do so in order to remove the brake shoes 5 For electric vehicles Remove the axle shaft See Axle Shaft and Oil Seal Removal Section 17 Page 17 1 For gasoline vehicles Remove the wheel hub assembly 6 Using needle nose pliers turn the clip retainer pin 1 90 to remove the s...

Page 67: ...the backing plate Figure 6 5 Page 6 3 After lubricating work slide back and forth against backing plate to ensure that it slides smoothly and easily Install rubber boot onto backing plate Reinstall rubber boot onto backing plate See following WARNiNG WARNING Apply grease carefully when performing the following steps Do not allow any grease to get onto the friction surfaces of the brake shoe pads o...

Page 68: ... See preceding WARNING BOSSES BOSSES 2817 Figure 6 6 Lubricate Raised Bosses 5 Use a small brush to carefully apply a light coat of white lithium NLGI 2 grease Dow Corning BR2 Plus or equivalent to each end of both brake shoes and into the slots in the brake shoe mounting block as shown Figure 6 7 Page 6 4 See preceding WARNING J 1 0 2819 Figure 6 7 Lubricate Shoes Page 6 4 2019 Transporter Mainte...

Page 69: ...refully apply a light coat of white lithium NLGI 2 grease Dow Corning BR2 Plus or equivalent to the brake actuator assembly as shown Figure 6 8 Page 6 5 See preceding WARNING 2799 Figure 6 8 Lubricate Actuator 2019 Transporter Maintenance and Service Manual Page 6 5 ...

Page 70: ...ing the retainer pin 2 into position Figure 6 10 Page 6 6 3 Attach the springs with hooks pointing outwards onto the trailing shoe already installed Then hold the leading shoe next to the trailing shoe correctly oriented and attach the springs to it Figure 6 11 Page 6 7 NOTE With brake shoe tips marked J10 oriented to the mounting block the stamping will be visible on one shoe only The other J10 s...

Page 71: ...ed to be adjusted vertically in the mounting slots 8 After the drum is installed make sure the axle and drum turn freely BRAKE ADJUSTMENT See General Warnings on page 1 2 See also Asbestos Dust Warning on page 6 1 CAUTION Pedal group adjustment must be within specifications prior to beginning brake adjustment Perform the appropriate pedal group adjustment For gasoline vehicles refer to For electri...

Page 72: ... cluster assemblies Figure 6 15 Page 6 8 4 5 4 5 2804 Figure 6 15 Rear Brake Adjustment Bolt 2803 Figure 6 16 Front Brake Adjustment Bolt 5 Use a torque wrench and a 7 mm 8 point socket or Club Car brake adjustment tool to turn the brake adjustment bolt 5 on each brake clockwise until it is tightened to 15 ft lb 20 3 N m then back off 5 clicks See following NOTE NOTE If a wheel can still be turned...

Page 73: ...9 22 11 10 11 16 17 14 2 TYPICAL 2 PLACES TYPICAL 2 PLACES 13 1 3 TYPICAL 4 PLACES 4 5 6 7 TYPICAL 2 PLACES TYPICAL 2 PLACES 8 18 15 12 2806 Figure 6 17 Front Manually Adjusted Brake Assembly 2019 Transporter Maintenance and Service Manual Page 6 9 ...

Page 74: ... 8 7 18 12 14 2 2903 Figure 6 18 Rear Manually Adjusted Brake Assembly BRAKE CABLE EQUALIZATION 1 Set park brake in the third tooth of the ratchet Place a wedge between the park brake pedal and brake pedal to prevent the park brake from disengaging while equalizing the brake cables Figure 6 19 Page 6 11 Page 6 10 2019 Transporter Maintenance and Service Manual ...

Page 75: ... CLUSTER ADJUSTMENT 1 To adjust the brake shoes turn the adjustment bolt counterclockwise five clicks 2 Repeat step 1 at other brake cluster s 3 Install the rubber dust covers 4 over the brake adjustment bolts 5 Figure 6 15 Page 6 8 and Figure 6 16 Page 6 8 4 Carefully support the vehicle with the lifting device remove jack stands and lower the vehicle to the ground TEST DRIVE VEHICLE 1 With the v...

Page 76: ...ck stands under the round tube crossmember of the frame to support vehicle 2 Release park brake 3 Loosen the equalizer retaining nuts 1 and 6 on the front equalizer rod 2 to slightly loosen the brake cable Figure 6 14 Page 6 8 4 Remove the front wheels and then the brake drums 5 Remove bow tie pin 17 and clevis pin 16 from brake cable Figure 6 21 Page 6 15 Figure 6 20 Page 6 13 6 Remove dust cap 6...

Page 77: ...BRAKE SYSTEM Brake Cluster Removal and Installation 6 6 11 10 1 2 3 TYPICAL 4 PLACES 4 5 9 8 7 2810 Figure 6 20 Front Spindle Assembly 2019 Transporter Maintenance and Service Manual Page 6 13 ...

Page 78: ...ter to the transaxle Figure 6 18 Page 6 10 7 Remove rear brake cluster assembly from transaxle REAR BRAKE CLUSTER INSTALLATION 1 Install in reverse order of disassembly Use new bow tie locking pins when installing brake cables See following CAUTION for Electric Vehicles CAUTION Clean any residual oil from the exposed end of the axle tube and from the oil seal area prior to installing the axle shaf...

Page 79: ... See General Warnings on page 1 2 See also Asbestos Dust Warning on page 6 1 18 8 B C 18 A 5 17 15 18 7 9 14 4 16 18 2 13 12 3 11 1 5 8 9 6 7 6 10 3189 Figure 6 21 Front Brake Cables and Equalizer 2019 Transporter Maintenance and Service Manual Page 6 15 ...

Page 80: ...is pin 6 and new bow tie pin 9 3 Route inner cable 8 through slot opening in passenger side of I beam A 4 Route outer cable 18 over rear brake equalizer rod B and through slot opening in driver side of I beam C 5 Route cables 8 and 18 along inside of frame rails towards front of vehicle Figure 6 21 Page 6 15 through gap between floorboard and tubular crossmember under cowl frame supports and criss...

Page 81: ...BRAKE SYSTEM Rear Brake Cables 6 REAR BRAKE CABLES 2 1 6 3 14 12 13 8 8 10 9 4 5 7 6 7 11 3191 Figure 6 23 Rear Brake Cables and Equalizer 2019 Transporter Maintenance and Service Manual Page 6 17 ...

Page 82: ...clevis pins 5 and E clips 6 Figure 6 23 Page 6 17 4 2 Remove cable 7 from plate under leaf spring 4 3 Note location of hangers 11 and pull cables out of vehicle REAR BRAKE CABLE INSTALLATION 1 Place the cable ends in the equalizer 3 Figure 6 23 Page 6 17 Route cables through hangers 11 in the same manner as the ones removed 2 At the rear wheel brakes connect the cables 7 to the brake actuator arms...

Page 83: ...le sheathing to release cables 1 from bracket 2 on rear axle Figure 6 25 Page 6 19 2 4 3 3 1 2 1 Rear axle not shown for clarity 3211 Figure 6 24 Disconnect Emergency Brake Cables at Rear Brake Drums 3212 Figure 6 25 Release Brake Cables from Rear Axle Bracket 4 Cut all wire ties securing cables to chassis 5 Remove the four locknuts 6 and bolts 2 and 4 that secure the emergency brake assembly 1 to...

Page 84: ...es to the chassis with wire ties 3 Adjust the emergency brake See Emergency Brake Adjustment on page 6 20 4 Perform all brake system inspections See Performance Inspection on page 10 1 EMERGENCY BRAKE ADJUSTMENT WARNING Make sure the brake pedal and park brake function properly before emergency brake adjustment CAUTION Perform the following procedure only on a level surface To avoid injury or prop...

Page 85: ...pedal system to make sure it has not been affected by adjustments to the emergency brake See Performance Inspection on page 10 1 7 Drive vehicle in a clear area and perform a stop test 8 Release accelerator pedal and immediately engage the emergency brake The vehicle should stop 9 If vehicle does not stop loosen set screw and tighten adjustment knob a small increment Repeat test 10 Repeat adjustme...

Page 86: ...Pagination Page 6 Emergency Brake System BRAKE SYSTEM Page 6 22 2019 Transporter Maintenance and Service Manual ...

Page 87: ...steering wheel 3 and steering column shaft 4 so when the steering wheel is removed it can be placed back in exactly the same position on steering column shaft 4 Loosen the steering wheel nut 5 and back it off approximately 1 4 inch 6 mm Do not remove the nut 5 Use the steering wheel puller to remove steering wheel 5 1 Place the puller anvil 6 through the top opening of the steering wheel Figure 7 ...

Page 88: ...taper before installing the steering wheel 1 Install the steering wheel 3 on the splines of the steering shaft 4 Be sure to align the match marks placed on the wheel and steering column shaft in step 3 above Figure 7 1 Page 7 2 2 Install the steering wheel nut 5 and tighten to 156 in lb 17 6 N m 3 Install the plate 2 and screws 1 Figure 7 1 Page 7 2 Tighten screws to 16 in lb 1 8 N m 4 Connect the...

Page 89: ...ON Steering Column 7 STEERING COLUMN See General Warnings on page 1 2 22 17 16 18 20 18 16 14 12 21 19 17 15 13 11 10 7 8 6 4 1 9 7 5 2 3 35 2609 Figure 7 3 Steering Column 2019 Transporter Maintenance and Service Manual Page 7 3 ...

Page 90: ...ssembly STEERING COLUMN ASSEMBLY 1 Insert bearing seat 18 into both ends of steering tube 20 Place a block of wood on bearing seat and tap lightly on block until bearing seat 18 is fully seated in steering tube 20 Figure 7 4 Page 7 5 2 Press the bearing 17 all the way into the bearing seat 18 using a steering column bearing press tool or a metal tube approximately six inches 15 2 cm long with a ma...

Page 91: ...hole in the universal joint 1 before sliding the spline into the universal joint While holding the steering column in place attach it to the frame using bolts 8 washers 7 and nuts 9 Figure 7 3 Page 7 3 Thread the nuts onto the bolts but do not tighten them 4 Install wide washer 35 washer 11 and screw 10 Tighten to 20 ft lb 27 N m Figure 7 3 Page 7 3 5 Install the bolt 2 and lock washer 3 on the up...

Page 92: ... right See following CAUTION CAUTION The drag link has both left and right hand threads The end of the drag link toward the spindle has left hand threads and the end toward the rack has right hand threads To prevent damage to threaded parts care should be taken when servicing the drag link 3 When all adjustments have been completed tighten the nuts 27 and 29 on the drag link assembly with an open ...

Page 93: ...le turning feel for any binding clunking or tight loose spots Listen for unusual noises Replace the rack and pinion as an assembly if any is found 4 In the event of an known impact and obvious visible damage is not found in the method described above disconnect the tie rods and or drag links from the spindles Turn the steering wheel from stop to stop While turning feel for any binding or tight loo...

Page 94: ...0 Page 7 10 3 Remove both bellows clamps 2 plastic wire ties 4 Remove the hex nut 29 and slide off the dust seal bellows 1 5 Remove the retaining ring 21 then slide off dust seal bellows 20 6 Remove the rack screw lock nut 15 rack guide screw 16 rack guide pressure spring 14 and the rack guide 13 Figure 7 10 Page 7 10 7 Remove the universal joint assembly from the pinion 8 by fully removing the bo...

Page 95: ...he ball bearing 9 has been damaged remove the external snap ring 10 Figure 7 10 Page 7 10 and press the bearing off Figure 7 8 Page 7 9 12 Remove retaining ring 19 and stop washer 18 then remove rack 17 from housing 6 Figure 7 10 Page 7 10 13 If the inner ball joint 3 is excessively worn remove the ball joint and tab washer 4 from the rack Figure 7 9 Page 7 9 13 1 Secure the rack in a vise using w...

Page 96: ... Install a new tab washer 4 and an inner ball joint 3 Figure 7 9 Page 7 9 Install the ball joint onto the rack by securing the rack in a vise using wood blocks between the rack and the jaws of the vise to protect the rack from damage Tighten the ball joint to 60 ft lb 81 N m 2 Bend the edges of the tab washer 4 up against the ball joint 3 Figure 7 9 Page 7 9 Page 7 10 2019 Transporter Maintenance ...

Page 97: ...Page 7 10 See preceding CAUTION 5 If the needle bearing 7 is damaged the steering box assembly must be replaced Figure 7 10 Page 7 10 6 Install pinion 8 and bearing 9 assembly into the housing 6 Figure 7 10 Page 7 10 Make sure the rack gear teeth will mesh with the gear teeth on the pinion The rack may need to be rotated slightly while lightly tapping on the pinion bearing assembly with a rubber m...

Page 98: ...tational resistance should measure 7 to 15 in lb 0 8 to 1 7 N m 11 4 If measured resistance does not equal 7 to 15 in lb loosen the lock nut 15 and tighten the screw 16 until it bottoms out then back the screw off one quarter turn Tighten the lock nut to 28 ft lb 38 N m Figure 7 12 Page 7 11 See following NOTE NOTE When tightening the lock nut 15 make sure the screw 16 does not change adjustment F...

Page 99: ...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 joint Install the bolt and lock washer on the upper universal joint and tighten it to 15 ft lb 20 N m 4 Tighten the steering rack mounting bolts 30 to 22 ft lb 29 8 N m Figure 7 10 Page 7 10 5 Install the drag link ball joint 23 on the spind...

Page 100: ...ead ball joints in deep enough may cause a ball joint to separate from the rod during adjustment or while being operated possibly resulting in loss of vehicle control and severe personal injury CAUTION The tie rod and drag link have 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 or drag link 2 Attach the tie rod bal...

Page 101: ...h a framing square At the floor or ground there should be an equal amount of space between each tire and the framing square Figure 7 14 Page 7 15 2 Loosen but do not remove the four nuts 32 that secure the leaf spring 6 to the bottom spring plate 29 Figure 7 19 Page 7 19 See also Figure 7 15 Page 7 15 A A B A 1 2 1 Proper Camber Adjustment 2 Improper Camber Adjustment 32 8 7 2868 Figure 7 14 Check...

Page 102: ...ce between the marks on the forward facing surfaces of the tires See following NOTE NOTE The front measurement must be less than the rear measurement 5 Subtract the measurement on the front of the tires from the measurement on the rear of the tires The difference is the toe in Proper toe in is 1 8 to 3 8 of an inch 3 2 to 9 5 mm 6 If adjustment is necessary loosen the jam nut on each tie rod ball ...

Page 103: ...stallation Section 8 Page 8 1 5 Adjust camber and toe in See Camber Adjustment on page 7 15 and Toe in Adjustment on page 7 16 KINGPIN AND STEERING SPINDLE REMOVAL 1 Remove the front hub See Front Hub and Wheel Bearings Removal on page 7 21 2 Remove nuts 20 and remove ball joints from spindles Figure 7 18 Page 7 18 Remove drag link ball joint See also Tie Rod and Drag Link Removal on page 7 14 3 R...

Page 104: ...n Components STEERING AND FRONT SUSPENSION 1 5 2 2 2 2 2 4 4 24 5 15 3 2 14 10 6 7 10 8 9 18 12 13 11 38 5 14 20 2610 Figure 7 18 Front Suspension Upper Portion Page 7 18 2019 Transporter Maintenance and Service Manual ...

Page 105: ...ION Front Suspension Components 7 15 17 3 16 1 2 33 19 34 5 7 4 35 14 8 26 27 28 27 25 6 31 32 29 9 13 23 14 30 5 17 37 36 2611 Figure 7 19 Front Suspension Lower Portion 2019 Transporter Maintenance and Service Manual Page 7 19 ...

Page 106: ... the shock absorber 15 free of the Delta A Plate 1 4 Remove the Delta A Plate 1 5 Inspect the bushings 2 and sleeves 3 and 4 in the Delta A Plate and replace them if necessary DELTA A PLATE INSTALLATION 1 Install the A Plate 1 in reverse order of removal Tighten the A Plate suspension bolts 10 and 24 to 20 ft lb 27 N m Figure 7 18 Page 7 18 2 Tighten shock absorber mounting nut 38 to 20 ft lb 27 1...

Page 107: ... WHEEL BEARINGS REMOVAL 1 Remove the front wheels See Wheel Removal on page 8 1 2 Remove the front wheel hubs 2 1 Remove dust cover 1 cotter pin 2 spindle nut 3 and flat washer 8 Figure 7 20 Page 7 21 2 2 Remove the hub assembly 4 from the spindle shaft Figure 7 20 Page 7 21 3 Remove the seal 6 and the bearings 5 from the hub Figure 7 20 Page 7 21 4 Inspect the bearing cups 7 If they are worn or p...

Page 108: ...t the spindle nut 3 Figure 7 20 Page 7 21 5 Tighten the spindle nut 3 until the hub is hard to turn then back the nut off until the hub turns freely Install a new cotter pin 2 Figure 7 20 Page 7 21 See following WARNING and NOTE WARNING Make sure to install and bend the cotter pin Failure to bend the cotter pin could result in the separation of the wheel hub from the spindle Loss of vehicle contro...

Page 109: ...operly aligned and adjusted WHEELS See General Warnings on page 1 2 WHEEL REMOVAL 1 Slightly loosen the lug nuts on the wheel to be removed 2 Raise the end of the vehicle from which the wheel is to be removed Make sure the wheels are off the ground See WARNING Lift only one end of the vehicle in General Warnings on page 1 2 3 Remove the lug nuts and remove the wheel WHEEL INSTALLATION 1 Install wh...

Page 110: ...void damage to the tire do not use excessive force when starting the bead over the edge of the rim 3 3 When top bead is free of the rim pull the bead from the bottom side of the rim up into the upper part of the rim well Insert the tire tool under the lower bead as shown Figure 8 1 Page 8 2 Detail C and carefully pry the lower bead over the rim flange 3 4 Once the lower bead is started over the ri...

Page 111: ...e rim from the valve stem side If there is no tire machine available use a rubber mallet and tire iron 5 Remove the valve core and position the tire so that both beads are on the rim flange narrow bead seats 6 Place the tire and wheel assembly against a wall in an upright position and push it against the wall while inflating the tire to the recommended pressure See Vehicle Specifications on page 2...

Page 112: ...8 Tires WHEELS AND TIRES Figure 8 2 Inflate Tire Page 8 4 2019 Transporter Maintenance and Service Manual ...

Page 113: ... damage or fluid leakage at the point where the shaft enters the shock absorber body Replace damaged or leaking shock absorbers Figure 9 1 Page 9 1 and Figure 9 4 Page 9 4 2 To remove a shock absorber remove the nut 1 cup washers 4 and rubber bushings 3 from the stem at the top of the shock absorber 3 Remove lower mounting hardware 1 3 and 4 on shock absorber lower mount 4 Compress the shock absor...

Page 114: ...hicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 3 Place a floor jack under the transaxle differential casing to support but not lift the drivetrain Raise it just enough to relieve tension on the shock a...

Page 115: ...and install the spring 3 Install the nut 11 and bolt 17 attaching the rear spring to the lower end of the shackle brackets 13 4 Install the nuts 7 and the U bolt 9 securing the spring to the shock mounting bracket 16 Install the shock mount bracket 6 angle bracket 13 and the U bolt 5 Tighten the nuts 7 on the U bolt 9 to 22 to 27 ft lb 30 to 37 N m 6 Install the nut 1 cup washers 4 and rubber bush...

Page 116: ...lti Leaf Springs REAR SUSPENSION 17 17 9 14 19 11 15 6 1 1 7 11 13 5 2 3 4 10 12 8 17 10 11 16 2987 Figure 9 4 Rear Suspension Assembly and Mounting Page 9 4 2019 Transporter Maintenance and Service Manual ...

Page 117: ...ace and properly installed Be sure that all nuts bolts and screws are tight Safety and information decals Check to ensure that all safety and information decals are in place Tires Visually inspect for wear damage and proper inflation on a daily basis See Vehicle Specifications on page 2 1 Battery ies Check electrolyte to ensure that it is at its proper level Figure 14 3 Page 14 10 Check battery po...

Page 118: ...RUN position and attempt to push the vehicle Motor braking should engage and limit rolling to no more than 1 to 3 mph 1 6 to 4 8 km h with the Forward Reverse switch in any position When walk away motor braking is engaged the reverse buzzer should emit a distinct pattern of beeps Pedal Up Motor Braking Accelerate the vehicle to full speed and then release the accelerator pedal Motor braking should...

Page 119: ...r the bed gently keeping entire body clear Do not drop the bed Failure to follow these instructions can result in serious personal injury Hot Do not attempt to service hot motor Attempting to do so can cause serious burns To avoid unintentionally starting the vehicle disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles on page 1 3 PERIODIC SERVICE...

Page 120: ... See Vehicle Specifications on page 2 1 Monthly service by owner or trained technician General vehicle Wash battery compartment and underside of vehicle Initial one time inspection by owner or trained technician after six weeks of use Batteries For vehicles newly equipped with the SPWS For vehicles newly equipped with the SPWS manually check battery electrolyte levels of all cells to verify correc...

Page 121: ...all cells to verify correct valve operation See page 14 8 Batteries If batteries are not performing as expected see the Batteries section in the maintenance and service manual Annual service by trained technician only or every 100 hours of operation whichever comes first Safety decals Check safety decals Replace if damaged or illegible 2019 Transporter Maintenance and Service Manual Page 10 5 ...

Page 122: ... slides Dry Moly Lube Semiannually by owner or trained technician or every 50 hours of operation whichever comes first Front suspension Chassis Lube EP NLGI Grade 2 Transaxle Check fill to plug level 22 fl oz 0 67 L SAE 30 WT API Class SE SF SG Oil or higher Annually by trained technician only or every 100 hours of operation whichever comes first Inspect front wheel bearings Repack as necessary Ch...

Page 123: ...ol CDT handheld programmer which replaced the IQDM series 2 handset How to use the CDT to troubleshoot the vehicle and to adjust controller parameters that affect vehicle behavior 1 7 8 3 4 5 6 12 2 11 10 9 1 Display Screen 5 Help Button 9 Favorites Button 2 Softkeys 6 Main Menu Button 10 Power Button 3 Key 7 System Port 11 Arrow Keys 4 Key 8 USB Port 12 SD card Slot 3115 Figure 11 1 CDT Overview ...

Page 124: ...screens give descriptions of adjustable parameters monitored variables and faults PC interface Files can be downloaded from a PC onto an Secure Digital SD card or into the programmer directly through its USB connector for installation into the controller Plot and Log The plot and log programs allow you to look at variables over time either in graphical format or as data files you can upload in a s...

Page 125: ...o the vehicle it begins loading controller information During this time the loading status is shown as a percentage the CDT s software version is given and status information icons appear in the upper right corner Once loading is complete the screen displays the Main Menu NOTE If the Power button is used to turn ON the handset and the handset is not connected to a vehicle the message No System Det...

Page 126: ... cause Relay DNC Check wiring replace relay M Shorted Replace controller Relay Driver Off Replace controller M Main Coil Open Broken or disconnected coil wire B or B a defective solenoid coil Replace solenoid Relay Driver On Replace controller Main Driver Off Replace controller Relay Welded Replace relay Main Driver On Replace controller Speed Sensor Check connection replace speed sensor Main Driv...

Page 127: ...WARE VERSION Displays the controller hardware version See following NOTE PROTOCOL VERSION Displays the controller protocol version PARAM BLOCK VERSION Displays a number that represents the default parameter settings at time of manufacture MFG DATE CODE Displays the date the controller was manufactured OS VERSION Displays the controller operating system software version See following NOTE SM VERSIO...

Page 128: ...n Mode 2 are programmed with the same procedures as Mode 1 The vehicle s top speed can be changed by selecting values 1 through 4 See chart below _ SPEED SETTING VEHICLE SPEED 1 8 0 mph 12 9 km h 2 12 mph 19 3 km h 3 15 mph 24 1 km h 4 17 mph 27 4 km h A vehicle programmed for speed setting 4 does not conform to ANSI Z130 1 American National Standard for Golf Cars Safety and Performance Specificat...

Page 129: ...4 7 mph 23 7 km h 16 7 mph 26 9 km h 4 7 6 mph 12 2 km h 11 6 mph 18 7 km h 14 6 mph 23 5 km h 16 6 mph 26 7 km h 5 7 5 mph 12 1 km h 11 5 mph 18 5 km h 14 5 mph 23 3 km h 16 5 mph 26 6 km h 6 7 4 mph 11 9 km h 11 4 mph 18 3 km h 14 4 mph 23 2 km h 16 4 mph 26 4 km h 7 7 3 mph 11 7 km h 11 3 mph 18 2 km h 14 3 mph 23 0 km h 16 3 mph 26 2 km h 8 7 2 mph 11 6 km h 11 2 mph 18 0 km h 14 2 mph 22 9 km...

Page 130: ... the fleet operator however these defined speeds can not override previously set values from other control mode options To avoid this after changing the control mode to 2 cycle power to the controller by placing the Run Tow Switch in the TOW position for 30 seconds Then return it to RUN 3 Deterrent Demo Mode Uses maximum speeds defined by the deterrent demo setting to demonstrate the automatic spe...

Page 131: ...ilable as a factory option or as a field kit 102962602 Kit Field Smartkey and can be ordered from Service Parts The code entries are used to activate Mode 2 M2 functions in the Parameters Menu Each vehicle has a unique code for placing the vehicle in this mode Once activated Mode 2 settings can be programmed using the same procedures as Mode 1 settings This allows the vehicle to be customized to p...

Page 132: ...3 I 86 V 74 J 87 W 75 K 88 X 76 L 89 Y 77 M 90 Z Vehicle Date of Manufacture Four digit number programmed by vehicle manufacturer Example 1401 represents Model Year 2014 week 1 Vehicle S N Six digit number programmed by vehicle manufacturer Vehicle Decal Decal number ranging from 0 to 999 and programmed by vehicle manufacturer Page 11 10 2019 Transporter Maintenance and Service Manual ...

Page 133: ... as a passenger in the vehicle Failure to heed this warning could result in severe personal injury or death The following parameters can be monitored in real time with the handset from the Monitor menu SPEED IN Indicates the approximate ground speed of the vehicle in miles per hour MPH THROTTLE Indicates the position of the accelerator pedal from 0 pedal not pressed to 95 and 100 pedal fully press...

Page 134: ... FORWARD position the handset should indicate that the reverse input is off When the Forward Reverse switch is placed in the REVERSE position the handset should indicate that the reverse input is on MODE SWITCH Indicates what position the Mode Switch is in On or Off WK AWAY RELAY Displays the state of the Walk Away Relay On or Off If the speed controller detects that the throttle is at 0 and the v...

Page 135: ...times the MAIN WELDED fault has been detected See Fault Descriptions on page 11 20 RELAY WELDED Displays the number of times the RELAY WELDED fault has been detected See Fault Descriptions on page 11 20 SPD SENSOR Displays the number of times the SPD SENSOR fault has been detected See Fault Descriptions on page 11 20 MAIN DRV ON Displays the number of times the MAIN DRV ON fault has been detected ...

Page 136: ...een detected See Fault Descriptions on page 11 20 DRVR OVERCUR Displays the number of times the DRVR OVERCUR fault has been detected See Fault Descriptions on page 11 20 RLY DRVR ON Displays the number of times the RLY DRVR ON fault has been detected See Fault Descriptions on page 11 20 RLY DRVR OFF Displays the number of times the RLY DRVR OFF fault has been detected See Fault Descriptions on pag...

Page 137: ...mps BDI Int Factor BDI Int Factor is an auto adjusting correction factor for estimating state of charge based upon the difference between the currently estimated state of charge and the Load Line SOC Open Circuit Voltage Start Open Circuit Voltage Start is the voltage as determined by the controller following a cycle of the Run Tow switch or coming out of sleep mode Open Circuit SOC Start Open Cir...

Page 138: ...mulated amp hours returned to the batteries from regenerative braking since initial vehicle start up Charge Amp Hours Displays amp hours removed from batteries since the last charge Charge Regen Amp Hours Displays amp hours returned to the batteries from regenerative braking since the last charge Trip Amp Hours Displays amp hours removed from batteries since trip amp hours was reset See Reset Trip...

Page 139: ...ng as a passenger in the vehicle Failure to heed this warning could result in severe personal injury or death PRESENT ERRORS FOLDER The Fault History folder displays all existing faults in chronological order An item in this folder can only be removed by remedying the fault As long as the fault exists it will be included in the Present Errors folder The number number in the upper right corner of t...

Page 140: ...esponds to the fault by limiting the vehicle speed to 1 2 of its normal top speed If the technician reaches the conclusion that the vehicle is running slowly because batteries are heavily discharged he has made an improper diagnosis of the problem The vehicle speed controller should be checked for fault codes before any service is performed The speed controller after detecting a fault will respond...

Page 141: ...ENSOR FAULT Throttle Applied Arm PWM 50 4 Speed pulses appear 10 MAIN DRIVER ON Continuous while KSI is ON 4 Condition clears 11 MAIN COIL OPEN Continuous while KSI is ON 3 Condition clears 12 MAIN DROPOUT Throttle applied 3 12 Throttle applied 13 MOTOR STALL Throttle applied 6 Speed pulses appear 14 MAIN DRIVER OFF Throttle applied 3 10 Condition clears 15 RELAY DNC WalkAway 2 13 Throttle applied...

Page 142: ... is already depressed when the key switch is turned to the ON position This fault when not caused by the operator can indicate that the pedal limit switch has failed closed 07 MAIN WELDED If the speed controller detects that the solenoid contacts are welded closed a main welded fault is detected 08 RELAY WELDED If the speed controller detects that the external Walk Away relay contacts are welded c...

Page 143: ...urned on or off with an CDT Factory default setting is off 17 CURRENT SENSE If there are problems with the armature current sensor circuitry a current sense fault is detected 18 M SHORTED If an uncontrolled current path is detected from the motor to B bypassing the MOSFETs an M shorted fault is detected 20 DRIVER OVERCURRENT If the current on the relay driver exceeds 120 mA or the current on the s...

Page 144: ...ure wiring is connected and inspect for damaged wires If the vehicle is not or no longer going to be equipped with these services change Control Mode setting to zero 0 LOCKOUT FAULT If the controller receives a signal that the charger interlock is activated while the vehicle is being driven the controller registers a lockout fault and may prevent the vehicle from operating What it means This is a ...

Page 145: ...nu can be useful in determining the cause of a vehicle problem however the fault history alone should not be the factor that determines when a component is replaced Some faults detected by the speed controller are not the result of a failed component and are instead the result of vehicle operator error If a fault appears in the fault history menu the trained technician should attempt to determine ...

Page 146: ...ters that cannot be seen at the OEM level It is recommended to enable Advanced Cloning FAVORITES The Favorites menu is accessed by pressing the Favorites key 9 Figure 11 1 Page 11 1 This menu can also be accessed by using the arrow keys to highlight Favorites and pressing the Select softkey to activate the menu Return to the Main Menu at any time by pressing the Main Menu key 6 The Favorites menu ...

Page 147: ...ered by the controller Exit menus with left arrow The left arrow key is used to navigate backwards within menus When set to Yes you can use the left arrow key to leave the presently displayed screen and return to the next higher i e previous screen using the left arrow key will eventually return you to the Main Menu When set to No you must use the appropriate softkeys Exit Cancel and the Main Menu...

Page 148: ...es on the CDT display screen or with the Log program to create a log file of variable values to view later in a spreadsheet program on a PC The first step is to add the desired items to the Plot Variable List or the Log Variable List While in the Monitor menu or Parameters menu highlight an item and press the Add to softkey In the next screen highlight Plot or Log and press the Select softkey to v...

Page 149: ...r HHP Settings menu Controller is in power down mode vehicle unused and not charged for 72 hours Connect charger or drive the vehicle a short distance and reconnect the handset to the vehicle Charger has been connected and charging for more than 10 minutes Disconnect charger wait 30 seconds and reconnect charger Loose vehicle wire harness connections Test Procedure 3 CDT Ports on page 11 29 Speed ...

Page 150: ...perty damage personal injury or death Index of Test Procedures 1 Handset Cord 2 Handset Cord Adaptor 3 CDT Ports TEST PROCEDURE 1 Handset Cord See General Warnings on page 1 2 1 Using a multimeter set for 200 ohms place the red probe into one of the terminals on the end of the cord with the square plug 2 Place the black probe on each of the pins one at a time on the plug on the other end of the co...

Page 151: ...t the CDT port mounted to the bottom of the dash panel Repair and replace parts as necessary 3 3 If no problem is found connect the four pin connector and install the center dash panel 3 4 Connect the batteries See Connecting the Batteries Electric Vehicles Section 1 Page 1 4 3 5 Align the keyed portion of the CDT plug with the CDT port and connect If the handset fails to function see CDT Troubles...

Page 152: ...11 Connection Tests CONTROLLER DIAGNOSTIC TOOL CDT Figure 11 3 Disconnect Four pin Connector Page 11 30 2019 Transporter Maintenance and Service Manual ...

Page 153: ...er simultaneously will sound three times to indicate a battery charging session has begun See following NOTE NOTE The number of flashes and beeps can vary depending on the Beep Option setting See Beep Option Section 11 Page 11 9 FEATURES Shunt Wound Motor The shunt wound motor unlike a series motor is designed so that the speed controller is able to vary the amount of current passing through the f...

Page 154: ...unction normally When the switch is in the TOW position power to the OBC and controller is shut off disabling the vehicle operating circuit and walk away braking allowing the vehicle to be towed Speed Calibration This function allows the vehicle s top speed to be calibrated in 0 1 mph 0 2 km h increments See M1 M2 Speed Cal Section 11 Page 11 7 Motor Protection Circuit The operator should never at...

Page 155: ...Pagination Page 12 General Information ELECTRICAL SYSTEM TROUBLESHOOTING Page 12 3 2019 Transporter Maintenance and Service Manual ...

Page 156: ...tions ELECTRICAL SYSTEM TROUBLESHOOTING SONIC WELD DIODE AND 10K OHM RESISTOR LOCATIONS 3119 Figure 12 1 Sonic Weld Diode and 10k Ohm Resistor Locations Approximate CA300 with ERIC Charging Page 12 4 2019 Transporter Maintenance and Service Manual ...

Page 157: ...lectrical system Troubleshooting Guide 1 is to be used in conjunction with the CDT handset Refer to the CDT Owner s Manual for operating instructions See following WARNING WARNING The vehicle operator should not monitor the CDT while the vehicle is in motion A technician can monitor the CDT while traveling as a passenger in the vehicle Failure to heed this warning could result in severe personal i...

Page 158: ...peed sensor Loose or disconnected 24 pin connector at speed controller or broken wire Repair and or connect the 24 pin connector to the speed controller Monitor Menu SPEED PULSES menu item indicates that speed pulses are OFF when the vehicle is in motion or Diagnostic Menu SPEED SENSOR fault code Failed motor speed sensor or failed magnet Test Procedure 13 Motor Speed Sensor on page 12 26 Loose or...

Page 159: ...en wire Repair and or connect the three pin connector to the MCOR Loose or disconnected 24 pin connector at speed controller or broken wire Repair and or connect the 24 pin connector to the speed controller Diagnostic Menu THROTTLE FAULT 1 fault code Failed MCOR Test Procedure 12 MCOR Voltage on page 12 24 Armature drive FET s field effect transistors inside speed controller have failed Replace th...

Page 160: ...he selected direction with the Forward Reverse switch Batteries require charging Place batteries on battery charger and allow them to fully charge Diagnostic Menu LOW BATTERY fault code Improperly maintained or failed batteries Section 14 Batteries Diagnostic Menu MOTOR STALL fault code Operator error Train operators to use the brake to hold the vehicle on a hill rather than holding the vehicle on...

Page 161: ...witch Test Procedure 8 Forward Reverse Rocker Switch on page 12 21 Solenoid loose wires Test Procedure 9 Solenoid Activating Coil on page 12 22 Solenoid failed coil Test Procedure 9 Solenoid Activating Coil on page 12 22 Solenoid failed solenoid diode Test Procedure 9 Solenoid Activating Coil on page 12 22 Speed controller thermal cutback Allow controller to cool and ensure that vehicle is not ove...

Page 162: ...ction Vehicle runs slowly Tires under inflated or flat tires See Wheels and Tires Section Wiring improperly wired Check vehicle wiring See Wiring Diagrams beginning on page Vehicle operates but motor braking function does not Speed sensor disconnected or failed Test Procedure 13 Motor Speed Sensor on page 12 26 Forward Reverse rocker switch improperly wired Test Procedure 8 Forward Reverse Rocker ...

Page 163: ...k wire in position 21 of the 24 pin connector and charge indicator light is powered by the controller with Run Tow switch in RUN The 2 amp fuse is powered directly by the batteries via the solenoid and carries BPV to the connected car device No switch is involved The term back probe refers to probing the side of a connector that the wire enters This is usually done when the connector must remain c...

Page 164: ...dset 1 Connect the CDT to the vehicle 2 Access the Monitor menu and select BATT VOLTAGE by using the SCROLL DISPLAY buttons The CDT should indicate at least 48 volts See following NOTE If not check for loose battery connections or a battery installed in reverse polarity Refer to Batteries on page 14 1 for further details on battery testing NOTE The voltage displayed through the CDT shows what the ...

Page 165: ...Test Procedures 12 1 2 3 4 6 5 7 8 Viewed from driver side of vehicle 1 RED probe to battery no 1 2 BLACK probe to battery no 6 3072 Figure 12 2 Battery Voltage Test 500 550 700 2019 Transporter Maintenance and Service Manual Page 12 13 ...

Page 166: ...ster leads to the positive post of battery no 1 and negative post of battery no 8 Figure 12 3 Page 12 14 Viewed from driver side of vehicle 1 RED probe to battery no 1 2 BLACK probe to battery no 8 2780a Figure 12 3 Battery Discharge Test TESTER Viewed from driver side of vehicle 1 RED probe to battery no 1 2 BLACK probe to battery no 8 2781a Figure 12 4 Battery Discharge Test 4 Turn the discharge...

Page 167: ...board computer 4 If the vehicle will not operate proceed to Run Tow Switch Test without the CDT Handset 5 If the CDT display screen begins to work after the vehicle has been driven turn the key switch to the OFF position and proceed to step 6 otherwise perform Run Tow Switch Test without the CDT Handset 6 With the CDT still connected to the vehicle place the Run Tow Switch in the TOW position and ...

Page 168: ... to connected car device Guardian Visage V3 Circuit and 15 amp fuse to electric powertrain Under Floorboard Near MCOR 20 amp fuse from DC DC converter to accessories Under Front Cowl 15 amp fuse to cab 10 amp fuse to brake lights horn and turn signals 7 5 amp fuse to headlights and taillights 10 amp fuse to 12 volt power strip and power point On Main Harness Near Controller Mounting Plate 30 amp f...

Page 169: ... 12 5 to 13 5 volts do the following Check 15 amp ATC fuse on controller mounting plate that supplies power to DC DC converter If fuse is good check converter For ATM Fuses Under Front Cowl Check sonic weld_4 in main wire harness Check key switch Check lockout relay For All Fuses Powered by the DC DC Converter Check sonic weld_16 in main wire harness TEST PROCEDURE 5 Circuit Breaker See General Wa...

Page 170: ...r model number 1520 Mid model year 2014 models without onboard computer OBC onboard charger Delta Quiq use controller model number 1520L 13 If there is no voltage at the number 3 pin 13 1 Check for voltage at the green wire on the circuit breaker switch 13 1 1 If there is 48 volts there is a broken wire between the tan wire on the circuit breaker and the number 3 pin on the 24 pin connector Use th...

Page 171: ...FUSED 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED 1 VOM Black Lead 2 VOM Red Lead 3 Wiring Diagram Symbol with Diode Stripe Orientation 4 Good Diode Probe Scenario A Conducts Current and Shows Continuity 5 Good Diode Probe Scenario B No Continuity 6 Bad Diode Meter Beeps In Either Direction Probe Scenarios A and B 1127 ...

Page 172: ...T function properly in order to test the MCOR limit switch with the CDT handset 5 Test the MCOR limit switch 5 1 Select FOOT INPUT on the Monitor menu by using the SCROLL DISPLAY buttons on the CDT 5 2 The CDT should indicate that FOOT INPUT is OFF when the accelerator pedal is not pressed regardless of the key switch position 5 3 With the key switch in the ON position press the accelerator pedal ...

Page 173: ...r It should show zero 0 volts with the accelerator pedal at rest Press the accelerator pedal and the green wire should show BPV passing through the MCOR to the controller for FOOT INPUT From the MCOR the blue wire supplies voltage BPV to pin 8 If not replace MCOR See MCOR Removal on page 13 5 TEST PROCEDURE 8 Forward Reverse Rocker Switch See General Warnings on page 1 2 NOTE This is a voltage tes...

Page 174: ... and related wiring 4 2 Brown Wire The brown wire should show BPV in FORWARD The brown wire should show zero 0 volts in NEUTRAL and REVERSE If the brown wire shows voltage in NEUTRAL the switch may have corrosion across the contacts or the switch has failed CLOSED and must be replaced See Forward Reverse Rocker Switch Removal on page 13 2 If the brown wire does not show BPV in FORWARD the switch m...

Page 175: ...ain hoist or floor jack Position jack stands under the frame crossmember between the spring mount and side stringer just forward of each rear wheel See WARNING Lift only one end in General Warnings on page 1 2 2 Turn the key switch to the ON position and place the Forward Reverse switch in the FORWARD position 3 Set a multimeter to 200 volts Place the black probe on the battery no 8 negative post ...

Page 176: ...f the reading is approximately 42 to 46 volts check continuity of circuit wires 5 Check 10k ohm resistor Set multimeter to 20k ohms Remove the 15 amp fuse With the red probe with insulation piercing probe still on the light blue wire pin 2 of the 24 pin connector place the black probe to the pink wire terminal in the 15 amp fuse holder The reading should be approximately 10 0k ohms If the reading ...

Page 177: ... the rear of the vehicle with a chain hoist or floor jack Position jack stands under the frame rails just forward of each spring mount See WARNING Lift only one end in General Warnings See also following WARNING WARNING The key switch should be placed in the OFF position and left in the OFF position for the duration of this test 2 With the batteries connected place Run Tow switch in RUN Using a mu...

Page 178: ...bout 3 feet 1 meter The reverse buzzer should sound and motor braking should engage while the vehicle is rolling 4 If the reverse buzzer does not sound and motor braking does not engage while the vehicle is rolling replace the Motor Speed Sensor Motor Speed Sensor Test with the CDT Handset CAUTION Perform the following procedure only on a level surface To avoid injury or property damage ensure tha...

Page 179: ...the motor speed sensor If the continuity is correct replace the speed controller Figure 12 8 Test 13 Speed Sensor Black White Wire 4 Check voltage at the red motor speed sensor wire 4 1 With Run Tow switch in the RUN position and using a multimeter set to 20 volts DC place the black probe on the battery no 8 negative post and place red probe on red wire terminal socket in three pin connector The v...

Page 180: ...om the 24 pin connector at the speed controller to the three pin connector at the motor speed sensor If the continuity is correct replace the speed controller 5 3 If reading is below 3 50 volts check the continuity of the wires and plug and replace the speed controller if necessary Figure 12 10 Test 13 Speed Sensor Light Green Wire 6 Reconnect the three pin connector at the motor speed sensor Usin...

Page 181: ...r jack Position jack stands under the frame crossmember between the spring mount and side stringer just forward of each rear wheel See WARNING Lift only one end in General Warnings on page 1 2 See also following WARNING WARNING Keep people and equipment clear from rotating rear wheels Do not allow persons under the car Contact with rotating rear wheels could result in serious personal injury 2 Wit...

Page 182: ...ischarge the controller See Disconnecting the Batteries Electric Vehicles Section 1 Page 1 3 2 Disconnect the 24 pin connector from the speed controller Inspect terminal ends inside plug to ensure they are in position and seated in plug housing If any terminals look like they are not pushed all the way into the connector gently push the terminals until they are firmly seated in the 24 pin connecto...

Page 183: ...ple White 18 gauge Pin 15 Yellow 18 gauge Test continuity of each wire and perform Pin 16 Open no wire Pin 17 Blue White 18 gauge Pin 18 Open no wire Pin 19 Orange White 18 gauge Pin 20 Purple 18 gauge Pin 21 White Black 18 gauge Supplies approximately 13 volts to the Guardian Visage unit CONNECTED CAR OUTPUT Approximately 13 volts measured between pin 1 and B terminal on controller Key switch eit...

Page 184: ...eter should read approximately 1k ohms 6 Slowly press the accelerator pedal while monitoring the multimeter The resistance should rise as the pedal is pressed When the pedal is all the way to the floor the multimeter should indicate between 5 67k ohms and 7 43k ohms 7 Set a multimeter to 20k ohms Insert the red probe of the multimeter into pin 15 yellow wire at the 24 pin connector Connect the bla...

Page 185: ...tion 1 Page 1 4 5 Set a multimeter to 200 volts DC insert the red probe of the multimeter into pin 8 green wire of the 24 pin connector See following CAUTION Connect the black probe to the B terminal of the speed controller or negative post of battery no 8 Figure 12 14 Page 12 33 CAUTION Do not fully insert probes into the 24 pin plug Doing so can result in a poor connection A Detail A Front of 24...

Page 186: ...NING Lift only one end in General Warnings on page 1 2 3 Disconnect the 24 pin connector at the speed controller 4 Place a jumper wire with an alligator clip between the B terminal of the speed controller use alligator clip for this connection and pin 19 orange white wire of the 24 pin connector Figure 12 15 Page 12 35 See following CAUTION CAUTION Do not fully insert probes into the 24 pin plug D...

Page 187: ...nd side stringer just forward of each rear wheel See WARNING Lift only one end in General Warnings on page 1 2 3 Disconnect the 24 pin connector at the speed controller 4 Set a multimeter to 200 volts DC insert the red probe of the multimeter into pin 10 brown wire of the 24 pin connector See following CAUTION Using an alligator clip connect the black probe to the B terminal of the speed controlle...

Page 188: ...wires in the wire harness Forward Reverse switch for proper operation See Forward Reverse Rocker Switch on page 12 21 Run Tow switch for proper operation See Run Tow Switch on page 12 15 A Detail A Front of 24 Pin Connector Figure 12 16 Test Pin 10 Black Wires Pin 1 See General Warnings on page 1 2 Pin 1 in the 24 pin connector provides a connection point for the key switch to the speed controller...

Page 189: ... in the ON position the multimeter should indicate full battery voltage approximately 48 volts With the key switch in the OFF position the reading should be zero volts 9 If any other reading is obtained check the following items Continuity of the wires in the wire harness Run Tow switch for proper operation See Run Tow Switch on page 12 15 Key switch for proper operation See Key Switch and MCOR Li...

Page 190: ...alligator clip connect the black probe to the negative terminal of battery 8 CAUTION Do not fully insert probes into the 24 pin plug Doing so can result in a poor connection 3 The reading should be 48 volts If the reading is zero volts replace the circuit breaker Pin 20 Smart Key Switch Only Voltage is supplied to Pin 20 when it is in the Mode position 1 With a multimeter set for 200 volts DC inse...

Page 191: ...d be approximately 48 volts full battery voltage 6 1 If the voltage reading is correct replace the reverse buzzer 6 2 If reading is zero volts check orange white wire continuity and connection at Pin 19 in 24 Pin connector 6 3 If there is no continuity in the orange white wire or the Pin 19 terminal in the 24 Pin connector is not properly seated repair or replace as required 6 4 If the orange whit...

Page 192: ...ccess the Monitor menu and select LED Driver by using the SCROLL DISPLAY buttons The CDT should indicate OFF 5 Reconnect charger DC cord to vehicle 6 In a few seconds the CDT should quickly display ON just once while the dash mounted charge indicator light flashes three times See following NOTE NOTE The CDT will still flash ON even with a failed or missing charge indicator light 7 If the CDT quick...

Page 193: ...no 2 3 Probe pin 2 red white wire It should show BPV If not check 2 amp fuse See following NOTE NOTE The red white wire has BPV with the Run Tow switch in either position 4 Probe pin 4 white black wire It should show approximately 13 volts supplied by the controller If not check wiring and then controller See following NOTE NOTE The white black wire only has voltage with the Run Tow switch in the ...

Page 194: ...ehicle on a level surface 2 Engage the park brake 3 Remove seat 4 Set a multimeter to 200 volts DC With the batteries connected connect the black probe to the negative post of battery no 8 5 Identify the 4 gauge black wire that connects the controller to the Emergency Stop switch 6 Probe the switch terminal for this black wire Figure 12 19 Page 12 42 7 With the Emergency Stop switch in the operate...

Page 195: ...h 4 From the back of the instrument panel push down on the retaining tabs surrounding the key switch 4 and remove the key switch cap 8 Using a 1 inch socket hold the key switch and remove the switch retaining nut 6 from the outside of the instrument panel Figure 13 1 Page 13 2 KEY SWITCH INSTALLATION 1 Position the key switch 3 and key switch washer 1 in the instrument panel then install and tight...

Page 196: ...rown orange and red green wires from the rocker switch 4 Press the locking tabs on each end of switch and push switch out of instrument panel FORWARD REVERSE ROCKER SWITCH INSTALLATION 1 Press the locking tabs on each end of the rocker switch and push switch into instrument panel 2 Connect the 18 gauge brown orange and red green wires to the rocker switch exactly as shown in the wiring diagram 3 I...

Page 197: ... TESTING THE Run Tow SWITCH See Test Procedure 3 Run Tow Switch on page 12 15 RUN TOW SWITCH REMOVAL 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles Section 1 Page 1 3 2 Using a 5 8 in 16 mm socket remove Run Tow switch boot hex nut 6 3 Remove Run Tow switch 10 and nut 9 from bracket 5 4 Disconnect the two pin connector 7 and remove switch ...

Page 198: ...een wires from the spade connectors 4 on the back of the circuit breaker CIRCUIT BREAKER INSTALLATION 1 Installation is reverse of removal Connect tan and green wires to the spade connectors 4 on the back of the circuit breaker See following NOTE NOTE The spade connectors are not polarity sensitive It does not matter what color wire goes to either of the spade connectors 2 Insert the circuit break...

Page 199: ...chain hoist or floor jack Place jack stands under the round tube crossmember of the frame to support vehicle 3 Disconnect the two pin and three pin connectors 1 from the MCOR 2 Figure 13 3 Page 13 5 4 Remove the two torx screws 3 securing the MCOR 2 to the plastic housing 4 on the chassis 5 Detach the two tabs from the plastic housing 4 and remove the MCOR 2 from vehicle GO 1 2 3 4 5 2646 Figure 1...

Page 200: ...rews from the reverse buzzer Remove the reverse buzzer from the center dash panel REVERSE BUZZER INSTALLATION 1 Install the reverse buzzer in the reverse order of removal Tighten screws to 4 in lb 0 45 N m 2 Connect the batteries See Connecting the Batteries Electric Vehicles Section 1 Page 1 4 SPEED CONTROLLER COVER REMOVING THE SPEED CONTROLLER COVER 1 Use a flathead screwdriver to pry up the ce...

Page 201: ...n but do not remove the two screws 1 that hold the solenoid 2 to the component mounting plate 5 Lift the solenoid 2 up and off of the component mounting plate 2 1 Figure 13 4 Solenoid SOLENOID INSTALLATION 1 Mount solenoid 2 onto component mounting plate with screws 1 Figure 13 4 Page 13 7 2 Tighten screws 1 to 60 in lb 6 8 N m 3 Using the wiring diagram install the wires washers and nuts onto the...

Page 202: ... N m Figure 13 5 Page 13 9 2 Using the wiring diagram install the multi pin connectors and all wires as illustrated Tighten bolts 8 to 13 5 ft lb 18 3 N m Tighten bolts 22 to 11 ft lb 14 9 N m Figure 13 5 Page 13 9 3 Install the speed controller cover See Installing the Speed Controller Cover on page 13 6 4 Connect the batteries See Connecting the Batteries Electric Vehicles Section 1 Page 1 4 5 P...

Page 203: ...ELECTRICAL COMPONENTS Speed Controller 13 7 20 8 12 23 17 22 18 2 13 3 24 1 6 4 21 10 15 16 14 5 9 19 25 11 11 2998 Figure 13 5 Speed Controller 2019 Transporter Maintenance and Service Manual Page 13 9 ...

Page 204: ...rument Panel Installation on page 4 9 4 Connect the batteries See Connecting the Batteries Electric Vehicles Section 1 Page 1 4 EMERGENCY STOP SWITCH See General Warnings on page 1 2 TESTING THE EMERGENCY STOP SWITCH See Test Procedure 20 Emergency Stop Switch on page 12 42 EMERGENCY STOP SWITCH REMOVAL NOTE The Emergency Stop switch button 1 is threaded onto the shaft of the E Stop switch 7 1 Dis...

Page 205: ...on is reverse of removal Make sure to install the protective boot 3 over the switch 7 before installation 2 Tighten screws 2 to 35 in lb 4 N m 3 Tighten terminal screws 5 to 75 in lb 8 5 N m 4 Connect the battery set See Connecting the Batteries Electric Vehicles Section 1 Page 1 4 2019 Transporter Maintenance and Service Manual Page 13 11 ...

Page 206: ...he bolts 1 Figure 13 7 Page 13 12 Figure 13 7 Headlight Bezel 6 Remove the headlight bezel 2 HEADLIGHT BEZEL INSTALLATION 1 Install the headlight bezel 2 to vehicle frame Figure 13 7 Page 13 12 2 Install the bolts 1 Tighten the bolts to 44 in lb 5 N m 3 Connect the headlight bulb and turn signal electrical connectors 4 Install the front fenders 5 Install the cowl 6 Connect the batteries Page 13 12...

Page 207: ...re 13 8 Page 13 13 2993C Figure 13 8 Halogen Headlight Bulb 4 Turn the headlight bulb clockwise 1 4 one quarter turn Remove the headlight bulb from the headlight assembly 2 HALOGEN HEADLIGHT BULB INSTALLATION CAUTION Do not touch the glass part of the headlight bulb Oil from fingertips can decrease the life of the headlight bulb 1 Install the headlight bulb 1 into the headlight lens 2 Figure 13 8 ...

Page 208: ...bulb clockwise 1 4 one quarter turn Remove the headlight bulb from the headlight lens 2 5 Remove the screws 3 6 Remove the headlight lens HALOGEN HEADLIGHT LENS INSTALLATION CAUTION Do not touch the glass part of the headlight bulb Oil from fingertips can decrease the life of the headlight bulb 1 Install the headlight lens 2 into the headlight bezel Figure 13 9 Page 13 14 2 Install the screws 3 Ti...

Page 209: ...0 Page 13 15 2993E Figure 13 10 LED Headlight 4 Remove the screws 2 5 Remove the LED headlight LED HEADLIGHT INSTALLATION 1 Install the LED headlight 1 into the headlight bezel Figure 13 10 Page 13 15 2 Install the screws 2 Tighten the screws to 22 in lb 2 5 N m 3 Install the electrical connector onto the LED headlight 4 Connect the batteries 5 Install the cowl LOCKOUT RELAY Figure 13 11 2019 Tran...

Page 210: ...5 Remove the screws 2 and the lockout relay LOCKOUT RELAY INSTALLATION 1 Install the lockout relay 1 and screws 2 Figure 13 11 Tighten the screws from 8 to 10 in lb 0 9 to 1 1 N m 2 Connect the wires to the lockout relay Figure 13 12 Pin Description Wire Color 1 Blue 2 White 3 White Black 4 Orange White Figure 13 12 3 Install the speed controller cover 4 Connect the batteries Page 13 16 2019 Trans...

Page 211: ...e wires from the walk away relay 1 Figure 13 13 5 Remove the screws 2 and the walk away relay WALK AWAY RELAY INSTALLATION 1 Install the walk away relay 1 and screws 2 Figure 13 13 Tighten the screws from 8 to 10 in lb 0 9 to 1 1 N m 2 Connect the wires to the walk away relay Figure 13 14 Pin Description Wire Color 1 Yellow 2 Tan 3 Green White 4 Pink Figure 13 14 2019 Transporter Maintenance and S...

Page 212: ...13 Walk Away Relay ELECTRICAL COMPONENTS 3 Install the speed controller cover 4 Connect the batteries Page 13 18 2019 Transporter Maintenance and Service Manual ...

Page 213: ...an immediately WARNING Wear safety glasses or approved eye protection when servicing the vehicle or battery charger Wear a full face shield and rubber gloves when working on or near batteries Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Ensure battery connections are clean and properly tightened See Battery ...

Page 214: ...ncorrect orientation of batteries i e terminal posts Poor fair or proper cleanliness of batteries Added electric accessories Use of a single point watering system SPWS MEASURING VOLTAGE OF BATTERY SET Set the multimeter to 200 volts DC Place the red probe on the positive post of battery no 1 and the black probe on the negative post of battery no 8 Record the reading BATTERY CELL NUMBERING 3 1 2 1 ...

Page 215: ...he battery installed Regrouping is now Club Car s standard battery replacement method Regrouping is the practice of placing batteries of similar condition together in one vehicle For example if there was an issue with the batteries in two cars and the battery test indicated three failed batteries in each car after removing the failed batteries there will be six good batteries remaining Install the...

Page 216: ...14 Battery Regrouping BATTERIES 3104 Figure 14 2 Battery Regrouping Process Flow Page 14 4 2019 Transporter Maintenance and Service Manual ...

Page 217: ...ve occurred in transit New batteries will not deliver their full capabilities until they have been discharged and recharged 50 to 70 times To obtain the maximum service life from new batteries restrict vehicles with new batteries to one hour of operation between charges for the first two months vehicle is in service Batteries should be fully charged before first use of new vehicle before first use...

Page 218: ...es equipped with the Single Point Watering System SPWS and one for vehicles without SPWS used in combination with Battery Watering Nozzle Gun Alternate Methods Reverse Osmosis Reverse osmosis involves forcing water through a membrane that allows water to pass while trapping solids The choice of membrane used determines the amount of solids or impurities that get trapped and hence the purity qualit...

Page 219: ...supply hoses Be sure to replace the deionizer filter cartridge as indicated by the water quality light The Deionizer system has a battery powered water quality light Deionizer filters have a limited life cycle and are disposable Life cycle of the filter will vary based on incoming water quality and water usage If the deionizer system is equipped with a water quality light press the button to check...

Page 220: ...ayed wires should be replaced Tighten battery terminals to proper torque See Connecting the Batteries Electric Vehicles on page 1 4 See following WARNING WARNING If battery wire terminals are damaged or corroded replace or clean them as necessary Failure to do so can cause them to overheat during operation and can result in fire property damage or personal injury 3 After use charge the batteries T...

Page 221: ...ee following NOTE NOTE Dispose of waste water properly 2 Check the electrolyte level weekly Figure 14 3 Add water only after charging unless the electrolyte level is below the top of the plates In this case add just enough water to cover the plates charge and then check the level again Never charge batteries if plates are exposed above electrolyte level For best battery life add only distilled wat...

Page 222: ... cause permanent damage Wash immediately Add water only after charging unless the electrolyte is below the level of the plates If the electrolyte level is below the level of the plates add just enough water to cover the plates and then charge the batteries After charging fill with water to the level indicator Filling a battery to the level indicator before charging will result in overfilling becau...

Page 223: ...er quality indicator light Replacement cartridge 104005901 Bottled distilled water with hand pump Club Car Part Number 104006101 is recommended for private consumer applications INITIAL MAINTENANCE OF THE SPWS After six weeks of operation remove the valves from the batteries and manually check the battery water level to ensure that the SPWS is not leaving any cells dry This initial electrolyte lev...

Page 224: ...ing NOTE NOTE This step also eliminates any trapped air from the water hose The water flow rate must be at least 2 gallons per minute 7 6 L per minute and the water pressure must be no more than 100 psig 689 5 kPa when static no flow for the SPWS to function properly 5 Check the water quality light on the deionizer to make sure the light is green in color indicating acceptable water quality If the...

Page 225: ...oupling into the space between the batteries and the car body Leaving the fill coupling on top of the battery bank or tucked between the batteries can result in coupling damage 5 Turn the water faucet off when finished filling the vehicle s BATTERY STORAGE See Storing the vehicle Section 3 Page 3 2 FLEET ROTATION Rotate vehicle usage It is very hard on batteries if the last vehicles in at night ar...

Page 226: ...ded the charge cycle will not be interrupted and the charger will be allowed to shut off automatically Placing the batteries on charge after each use reduces 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 discharged and recharged 50 to 70 times If they are excessively discharged ...

Page 227: ... the possibility of driving the vehicle while the charger is plugged in and potentially damaging the vehicle and charger Long Term Storage Charge This charger is designed to be left connected to AC power during off season or long term storage Be sure to check the charger monthly to ensure the charger is operating correctly during storage The charger will enter maintenance mode if supported by the ...

Page 228: ... of the charger lights will turn on and then off 4 2 The AC on symbol will turn on 4 3 The current algorithm will display for 11 seconds 2388B Figure 15 1 80 Charge Light 5 If the 80 charge light flashes the current algorithm is 72 Figure 15 1 NOTE The 80 charge light will flash 7 times pause then flash 2times 2387B Figure 15 2 Number 3 Light 6 If the number 3 light flashes the current algorithm i...

Page 229: ...wire to the battery post until the batteries start to charge 7 2 When the batteries start to charge disconnect the main positive battery wire 8 Disconnect the AC cord 9 Connect the main positive battery wire 10 If equipped connect the DC DC converter connector 11 Set the Run Tow switch to RUN THE CHARGE CIRCUIT The charge circuit consists of the onboard charger batteries and charger information li...

Page 230: ...r work to the manufacturer or qualified personnel This appliance is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety Children should be supervised to ensure that they do not play wi...

Page 231: ...ts immediately Failure to heed this warning could result in a fire property damage severe personal injury or death Do not operate the charger if it has received a sharp blow was dropped or otherwise damaged in any way Have worn cut or damaged power cords or wires replaced immediately Install surge arrestors on incoming AC power lines Surge arrestors will help protect electrical components in the c...

Page 232: ...lk phase Ammeter Amber Flashing High internal charger temperature Output reduced Also displays algorithm 1 through 6 for 11 seconds if no battery is connected Solid Bulk charge phase complete 80 charged In Absorption phase 80 Charge Amber Flashing 1 With no battery connecte indicates algorithm selected by number of flashes 2 With battery connected indicates battery being charged TABLE CONTINUED ON...

Page 233: ...wer good AC on Amber Flashing Low AC Voltage Check Voltage and power cord length refer to guidelines See AC Power Connection on page 15 8 Fault Red Flashing 1 Solid Red Charger Hardware Failure requires charger to be replaced 2 Flashing Red Charge Cycle Caution AC Voltage DC Voltage Ambient Temperature Charge Cycle Timers 2019 Transporter Maintenance and Service Manual Page 15 7 ...

Page 234: ...le has been driven and recharged from 20 to 50 times Vehicles should be restricted to 40 to 50 amp hours of discharge between charges until the batteries have been properly seasoned 20 to 50 charge cycles For maximum battery life Club Car recommends that electric vehicles always be recharged after 40 to 50 amp hours of discharge or each night in order to avoid deep discharging the batteries Chargi...

Page 235: ... annual periodic service WARNING If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to make necessary repairs could result in fire property damage severe personal injury or death Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the charger Do not expose charger to oil dirt mud or direct hea...

Page 236: ...r interrupt AC power for 15 seconds Battery Low Voltage Ensure battery set is rated 48 volts and composed of 24 cells Also check the voltage of each individual battery See Battery Voltage Using Multimeter on page 15 11 If not replace with correct battery set Reset charger interrupt AC power for 15 seconds Charge Timeout caused by battery pack not reaching required voltage Charger output was reduce...

Page 237: ...nce may indicate a problem in the vehicle electrical system brakes or battery charger If the problem is not found in the vehicle or charging system proceed to the on charge voltage test If the green battery icon does not change to a slow flash the batteries should be tested further using the on charge voltage test TEST PROCEDURE 3 On Charge Battery Voltage Using Charger And Multimeter When the bat...

Page 238: ...er 10 gauge black wire See following NOTE NOTE The 10 gauge red wire from the charger to the solenoid has an in line 30 amp fuse 3 When finished connect DC cord plug to the charger lead CHARGER REPAIRS See General Warnings on page 1 2 NOTE The high frequency charger offers no replacement parts If necessary the charger must be replaced See Onboard Charger Removal And Installation on page 15 12 ONBO...

Page 239: ...the four lock nuts 5 securing charger to charger mounting plate Tighten to 40 in lb 5 4 N m 3 Connect the AC and DC connector 4 Connect 8 pin grey connector 5 Install wire ties to secure connectors to the charger P clip 6 Connect the batteries See Connecting the Batteries Electric Vehicles on page 1 4 2019 Transporter Maintenance and Service Manual Page 15 13 ...

Page 240: ...Pagination Page 15 Onboard Charger Removal And Installation BATTERY CHARGER Page 15 14 2019 Transporter Maintenance and Service Manual ...

Page 241: ...rcuits See General Warnings on page 1 2 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles Section 1 Page 1 3 2 Disconnect wires from terminals on motor using two wrenches to prevent posts from turning 3 With a multimeter set to 200 ohms place black probe on motor housing Scratch through paint to ensure a good connection Place red probe on A1 ...

Page 242: ...e 16 3 3 Connect the batteries See Connecting the Batteries Electric Vehicles Section 1 Page 1 4 TEST PROCEDURE 3 Field Circuit Open See General Warnings on page 1 2 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles Section 1 Page 1 3 2 Disconnect wires from the F1 and F2 terminals on the motor using two wrenches to prevent posts from turning...

Page 243: ...th 1000 lb 454 kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 1 Position floor jack under hitch bracket or frame 2 Carryall 700 shown 286...

Page 244: ...n fingers under motor when sliding motor off of the input shaft in step 9 Fingers may get pinched when motor disengages 10 Carefully slide the motor away from the transaxle until the motor spline disengages the input shaft and remove the motor from the vehicle Figure 16 4 Speed Sensor Magnet Figure 16 5 End Cap Removal Page 16 4 2019 Transporter Maintenance and Service Manual ...

Page 245: ...magnet See Speed Sensor Magnet Inspection on page 16 9 Figure 16 6 Brush Springs Positioning Figure 16 7 Armature Removal 4 Orient the motor so that the splined end of the armature is facing down 5 Remove the four end cap bolts The weight of the motor housing will cause it to drop when the bolts are removed See following CAUTION CAUTION The motor housing will drop when the bolts are removed Do not...

Page 246: ...nt support the armature while the press is activated 9 Inspect the armature for wear and damage See Armature Inspection and Testing on page 16 7 10 Inspect the motor frame and field windings See Motor Frame and Field Windings Inspection on page 16 8 11 Remove the brush rigging 11 1 Mark the brush terminal posts A1 and A2 11 2 Remove the two nuts securing the brush terminals A1 and A2 to the end ca...

Page 247: ...ine original cause of failure Slight roughness of the commutator can be polished smooth with 400 grit or finer sandpaper See following CAUTION and NOTE CAUTION Do not use emery cloth to polish the commutator Particles of emery are conductive and may short circuit the commutator bars Do not use oil or lubricants on the commutator or brushes NOTE Oil on the commutator may indicate a faulty transaxle...

Page 248: ...e brush springs 18 Figure 16 13 Page 16 10 Replace springs that are discolored from heat light gold or blue tinted 4 Test the brush springs for proper tension 4 1 Place a C shaped steel plate 1 on a scale 2 4 2 Place the end of the C shaped plate 1 so that it is between the spring and the brush 4 3 Gently pull the scale 2 to obtain the spring tension reading See following CAUTION CAUTION When chec...

Page 249: ...required Bearing Inspection NOTE Replacement of the end cap bearing is highly recommended if the end cap is removed from the motor The following procedure is provided as a guideline for determining general bearing failure 1 Remove the motor from the vehicle See Motor Removal Section 16 Page 16 3 2 Remove the bearing by performing steps 1 through 13 of Motor Disassembly on page 16 5 3 Use a clean c...

Page 250: ...16 Motor Component Testing and Inspection MOTOR 22 2 4 1 23 13 10 11 9 12 18 16 21 14 15 17 7 6 19 20 Figure 16 13 Motor Page 16 10 2019 Transporter Maintenance and Service Manual ...

Page 251: ... the bearing apply pressure only to the outer race when installing the bearing 1 2 Install the retaining ring to secure the bearing 2 Install the brushes and brush rigging See following NOTE NOTE When installing new brushes remove and replace brushes one at a time This method ensures the terminals and brushes will be properly positioned in the rigging When replacing brushes replace all eight brush...

Page 252: ...each brush 5 Align the match marks on the end cap 20 and the motor frame 14 and secure with four bolts Figure 16 13 Page 16 10 Tighten bolts to 130 in lb 14 7 N m 6 Install the speed sensor magnet 12 with bolt 13 Tighten to 65 in lb 7 3 N m 7 Install the speed sensor 1 with one screw 2 finger tight Figure 16 16 Page 16 13 8 Install clamp 3 onto sensor wires 4 and secure with other screw 5 finger t...

Page 253: ...t 2 1 Squeeze approximately 1 2 inch 1 3 cm of moly teflon lubricant from tube onto a putty knife as shown Figure 16 17 Page 16 14 2 2 Rotate wheels to rotate input shaft 2 3 Apply motor coupling grease evenly to the rotating input shaft starting at approximately 1 8 inch 3 1 mm from the end of the shaft and working back toward the transaxle away from the end of the shaft Figure 16 18 Page 16 14 2...

Page 254: ...ge 16 16 Continue tightening by hand until the motor is seated in the transaxle housing See following CAUTION and NOTE CAUTION Make sure the motor is properly seated in the transaxle housing NOTE Failure to install and tighten the motor mounting bolts in the proper sequence and to the proper tightness may result in motor noise during operation 3 4 Tighten the right bolt 1 to 65 in lb 7 3 N m Figur...

Page 255: ...g nuts 8 Lift vehicle and remove jack stands Lower vehicle to the floor and tighten lug nuts using a crisscross pattern See Wheel Installation Section 8 Page 8 1 9 Connect the batteries See Connecting the Batteries Electric Vehicles Section 1 Page 1 4 10 Place the Run Tow switch in the RUN position 11 Inspect the vehicle for proper operation See following WARNING WARNING Make sure that the vehicle...

Page 256: ...16 Motor Installation MOTOR 2 3 1 4 Viewed From Driver Side Figure 16 21 Motor Tightening Sequence Page 16 16 2019 Transporter Maintenance and Service Manual ...

Page 257: ...s at the front wheels Loosen lug nuts on rear wheels and lift the rear of the vehicle with a chain hoist or floor jack Place jack stands under the axle tubes to support the vehicle See WARNING Lift only one end in General Warnings on page 1 2 3 Remove the rear wheel and brake drum See Wheel Brake Assemblies Section and Wheels and Tires Section 4 Use 90 internal snap ring pliers to remove the inter...

Page 258: ...Figure 17 5 Page 17 3 If the bearing in a Type G transaxle is worn or damaged the entire axle shaft assembly 1 or 2 must be replaced 1 2 Figure 17 1 Remove Internal Retaining Ring Figure 17 2 Axle Seal and Adapter Ring Removal 15 39 A A Adapter Ring Lip Figure 17 3 Axle Seal and Adapter Ring Figure 17 4 Axle Seal and Adapter Ring Installation Page 17 2 2019 Transporter Maintenance and Service Manu...

Page 259: ...ng and Shaft 17 1 3 6 5 14 15 24 26 13 33 36 32 8 10 11 12 20 18 19 16 16 16 17 23 21 25 36 22 35 13 27 30 31 29 2 5 3 8 36 15 27 30 28 Figure 17 5 Transaxle Type G 2019 Transporter Maintenance and Service Manual Page 17 3 ...

Page 260: ...the shaft splines with the splined bore of the differential side gear 27 Figure 17 5 Page 17 3 Continue advancing the shaft until the bearing on the axle is firmly seated within the axle tube hub seat 2 2 Use a pair of snap ring pliers to install the retaining ring 6 inside axle tube hub so that it seats against the axle bearing assembly and into the machined slot in the inside wall of the axle tu...

Page 261: ... and the side stringer just forward of each rear wheel Lower the vehicle to let the jack stands support the vehicle Figure 17 6 Page 17 5 See WARNING Lift only one end of the vehicle in General Warnings on page 1 2 4 Remove the rear wheels then thread one lug nut onto a stud on each rear hub This will keep the brake drums on the hubs 5 Remove the bow tie pins 1 brake cable clevis pins 2 and cable ...

Page 262: ...ed to raise the vehicle lift the vehicle high enough to permit easy access and clearance for removal of the motor If a floor jack was used to raise the vehicle lower the transaxle enough to permit easy access and clearance for removal of the motor 10 Remove the three motor mounting bolts Figure 17 11 Page 17 7 and the motor positioning bolt Figure 17 12 Page 17 7 mounting the motor to the transaxl...

Page 263: ...est on the floor 13 Remove the U bolts attaching the transaxle to the leaf springs Figure 17 10 Page 17 7 14 Carefully lift each end of the transaxle off its positioning pin on the leaf spring and slide the transaxle to the rear and out of the vehicle 15 Drain the lubricant from the transaxle and remove the axle shafts See Axle Shaft and Oil Seal Removal on page 17 1 See following NOTE NOTE Recycl...

Page 264: ...sembly 19 Lift intermediate gear assembly and differential gear case unit out simultaneously Figure 17 5 Page 17 3 See following CAUTION CAUTION Do not damage gears Use extreme care when handling them 5 Use a bearing puller or arbor press to remove bearings 16 from the input pinion gear If the oil seal 10 is damaged replace it Figure 17 5 Page 17 3 See also Figure 17 13 Page 17 8 See following CAU...

Page 265: ...al pin 31 by pushing pin through differential gear case from one side Figure 17 5 Page 17 3 See also Figure 17 15 Page 17 9 8 5 Remove the idler gears 1 and 2 and thrust plates 3 and 4 Figure 17 16 Page 17 9 1 5 6 26 2 8 7 3 4 Figure 17 15 Differential Pin Figure 17 16 Left Differential 8 6 Remove the differential gears 5 and 6 and thrust plates 7 and 8 8 7 Inspect the bearings 13 of the different...

Page 266: ...urface of housing 8 2 Install left half of transaxle housing 20 Figure 17 5 Page 17 3 8 3 Install eleven bolts 24 in the case housing and tighten to 19 ft lb 25 7 N m Type G transaxles have no shims or gasket 8 4 Install axle tube 14 and 35 with bolts 8 Figure 17 5 Page 17 3 Tighten the bolts to 37 ft lb 50 2 N m 9 Install the brake assemblies as instructed See Wheel Brake Assemblies Section 10 Ap...

Page 267: ...ng a floor jack raise the differential while guiding the leaf springs into the rear spring shackles Then raise the jack stands to support the transaxle 6 Connect the four motor wires Tighten the retaining nuts to 65 in lb 7 3 N m Use two wrenches to prevent the posts from turning See following NOTE NOTE If the motor wires were not tagged when disconnected refer to the wiring diagram for proper con...

Page 268: ... Transaxle Installation TRANSAXLE WARNING Make sure that the vehicle does not operate when the Forward Reverse switch is in the NEUTRAL position Page 17 12 2019 Transporter Maintenance and Service Manual ...

Page 269: ...tion Wire Color BLK Black BLU Blue LT BLU Light Blue BRN Brown GRAY Gray GRN Green ORG Orange PINK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow BLK_LT_BLUE Black with Light Blue Stripe BLK_ORG Black with Orange Stripe BLK_PINK Black with Pink Stripe BLK_WHT Black with White Stripe BLK_YEL Black with Yellow Stripe BLU_WHT Blue with White Stripe BRN_WHT Brown with White Stripe GRN_RED Green ...

Page 270: ..._BLK Orange with Black Stripe ORG_WHT Orange with White Stripe PUR_WHT Purple with White Stripe RED_GRN Red with Green Stripe RED_WHT Red with White Stripe RED_YEL Red with Yellow Stripe WHT_BLK White with Black Stripe Page 18 2 2019 Transporter Maintenance and Service Manual ...

Page 271: ...ELECTRIC MAIN HARNESS Wiring Diagrams Electric Main Harness 18 ...

Page 272: ... Page intentionally left blank ...

Page 273: ...ELECTRIC INSTRUMENT PANEL HARNESS Wiring Diagrams Electric Instrument Panel Harness 18 ...

Page 274: ... Page intentionally left blank ...

Page 275: ...ELECTRIC ACCESSORIES HARNESS Wiring Diagrams Electric Accessories Harness 18 ...

Page 276: ... Page intentionally left blank ...

Page 277: ...allation 6 14 removal 6 14 emergency brake system 6 19 adjustment 6 20 installation 6 20 removal 6 19 pedal height adjustment electric 5 8 installation 5 2 removal 5 1 shoe installation 6 6 removal 6 1 braking motor see regenerative braking 12 2 braking regenerative see regenerative braking 12 2 bumper installation 4 8 removal 4 8 C CAUTION definition of 1 1 CDT amp hours 11 9 anti tamper speed 11...

Page 278: ... diode locations 12 4 diode solenoid testing 12 22 diode wire harness testing 12 18 drive motor see motor 16 1 E E stop switch installation 13 11 removal 13 10 testing 12 42 electric bed lift installation 4 21 removal 4 21 electric motor see motor 16 1 electrical system 12 1 testing circuits 12 11 electrolyte tray installation 4 26 removal 4 26 F fender tailskirt rear removal 4 17 floor mat instal...

Page 279: ...ng 12 29 see test procedures motor 16 1 walk away braking 12 1 motor braking see regenerative braking 12 2 motor controller output regulator MCOR testing 12 20 12 24 motor controller output regulator 3 MCOR installation 13 5 removal 13 5 P park brake adjustment electric 5 9 installation 5 5 removal 5 4 pedal group adjustment electric 5 8 R rack and pinion assembly 7 10 disassembly 7 8 installation...

Page 280: ...t procedures charger AC power and continuity test of AC circuit 15 12 DC circuit continuity test 15 12 test procedures electric vehicle 15 amp fuse 12 16 24 pin connector 12 30 4 pin connector 12 41 batteries voltage check 12 12 battery pack voltage under load 12 14 charge indicator light 12 40 charger interlock 12 23 circuit breaker 12 17 E stop switch 12 42 Forward Reverse rocker switch 12 21 ke...

Page 281: ...lay testing 12 39 walk away relay 13 17 installation 13 17 removal 13 17 WARNING definition of 1 1 water level see batteries electrolyte level 14 10 wheel installation 8 1 removal 8 1 see also tire 8 3 wiring diagrams 18 1 2019 Transporter Maintenance and Service Manual Index 5 ...

Page 282: ...NOTES ...

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