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POWERDRIVE BATTERY CHARGER

General Information

Page 14-2 1998/1999 PowerDrive Plus Maintenance and Service Supplement

14

POWERDRIVE CHARGING FEATURES

• Charge Interlock

PowerDrive Battery Charger DC plugs have three pins rather than two blades that most standard charger
plugs have. Two of these pins are the positive and negative leads as on standard chargers; the third pin is a
sensing lead which is the communication link between the charger and the onboard computer. When the
charger plug is inserted into the vehicle receptacle, the onboard computer locks out the vehicle’s drive sys-
tem. This prevents the possibility of driving the vehicle while the charger is plugged in and potentially dam-
aging the vehicle and charger.

• Long Term Storage Charge

PowerDrive Plus vehicles and PowerDrive Chargers are designed to be left connected, with AC power to the
charger, during off-season or long term storage. The onboard computer will automatically activate the
charger every 15 days. To return the vehicle to service, disconnect the DC cord from the vehicle, wait 15 sec-
onds and then plug the DC cord back in. The charger will activate. Allow the vehicle to complete one full
charge cycle before putting it into service.

• Charger Disconnect

The computer communication pin is shorter than the positive and negative pins in the charger DC plug. In the event
the charger plug is pulled from the receptacle while the charger is in operation, the computer communication link
will be disconnected first, which will shut the charger off before the positive and negative pins disconnect. This will
help prevent possible damage to the plug and receptacle due to arcing.

•

SHORTLY AFTER CHARGING BEGINS, THE CHARGER WILL SHUT OFF IN ORDER TO RUN A SELF-DIAGNOSTIC
PROGRAM (AMMETER WILL DROP TO ZERO). CHARGING WILL RESUME IN A FEW MOMENTS (AMMETER
RETURNS TO PREVIOUS RATE OF CHARGE). THIS WILL BE REPEATED AT ONE HOUR AND AT TWO HOURS INTO
THE CHARGE CYCLE.

Figure 14-1 PowerDrive Battery Charger

NOTE

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Содержание 1998 DS

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

Страница 2: ......

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

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

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

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

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

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

Страница 9: ...HICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL AND MECHANICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MA...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 49: ...from the multi step potentiometer 2 Test the multi step potentiometer arm and fixed contacts for proper adjustment 2 1 With a dry erase marker completely coat each of the fixed contacts 2 2 Sweep the...

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

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

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

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

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

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

Страница 56: ...12...

Страница 57: ...TACT WITH SKIN EYES OR CLOTHING ANTIDOTES EXTERNAL FLUSH WITH WATER CALL A PHYSICIAN IMMEDIATELY INTERNAL DRINK LARGE QUANTITIES OF MILK OR WATER FOLLOW WITH MILK OF MAGNESIA OR VEGETABLE OIL CALL A P...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 72: ...13...

Страница 73: ...E AN EXPLOSION BATTERY POISON CONTAINS ACID CAUSES SEVERE BURNS AVOID CONTACT WITH SKIN EYES OR CLOTHING ANTIDOTES EXTERNAL FLUSH WITH WATER CALL A PHYSICIAN IMMEDIATELY INTERNAL DRINK LARGE QUANTITIE...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 98: ...14...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 128: ...16...

Страница 129: ...Club Car R NOTES...

Страница 130: ...Club Car R NOTES...

Страница 131: ......

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

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