Club Car TransPorter 4 Manual

2019Transporter
MaintenanceandService
Manual
ElectricVehiclewithQuiQ™ ™
™Charger
ManualNumber105355114
EditionCodeB

FOREWORD
ClubCarvehiclesaredesignedandbuilttoprovidetheultimateinperformanceefciency;however,proper
maintenanceandrepairareessentialforachievingmaximumservicelifeandcontinuedsafeandreliableoperation.
ThismanualprovidesdetailedinformationforthemaintenanceandrepairoftheTransportervehicles,andshouldbe
thoroughlyreviewedpriortoservicingthevehicle.Theproceduresprovidedmustbeproperlyimplemented,andthe
DANGER,WARNING,andCAUTIONstatementsmustbeheeded.
Thismanualwaswrittenforthetrainedtechnicianwhoalreadypossessesknowledgeandskillsinelectricaland
mechanicalrepair.Ifthetechniciandoesnothavesuchknowledgeandskills,attemptedserviceorrepairstothe
vehiclemayrenderthevehicleunsafe.Forthisreason,ClubCaradvisesthatallrepairsand/orservicebeperformed
byanauthorizedClubCardistributor/dealerrepresentativeorbyaClubCarfactory-trainedtechnician.
ItisthepolicyofClubCartoassistitsdistributorsanddealersincontinuallyupdatingtheirserviceknowledgeand
facilitiessotheycanprovidepromptandefcientserviceforvehicleowners.Regionaltechnicalrepresentatives,
vehicleserviceseminars,periodicservicebulletins,maintenanceandservicemanuals,andotherservicepublications
alsorepresentClubCar’scontinuingcommitmenttocustomersupport.
ClubCaroffersafulllineoftrainingandcontinuingeducationclassesfortechnicianswhowanttolearnmoreabout
ourproducts.Formoreinformation,contactyourlocaldealerorClubCar'sT echnicalServicesdepartmentfora
listofupcomingclasses.
Thismanualcoversallaspectsoftypicalvehicleservice;however,uniquesituationssometimesoccurwhenservicinga
vehicle.Ifitappearsthataservicequestionisnotansweredinthismanual,pleasecontactyournearestauthorized
ClubCardealerordistributorforassistance.
TondyourlocalauthorizedClubCardealer,visitwww.clubcardealer.com,call1-800-ClubCar(258–2227),orscan
thisQuickResponse(QR)codetobetakentotheClubCardealerlocator.RefertoFigure1.DownloadaQRcode
readersuchasRedLaserorBarcodeScannertoyourcellphoneortablet.
Ifyouwouldprefertowritetous,directyourletterto:ClubCarLLC,Attention:MarketingServices,P .O.Box204658,
Augusta,Georgia30917-4658USA.
_
DealerLocatorQRCode
Copyright©2019
ClubCarisaregisteredtrademarkofClubCar,LLC
ThismanualeffectiveJuly,2019
2019TransporterMaintenanceandServiceManualPagei

FOREWORD
TECHNICALPUBLICATIONCUSTOMERSATISFACTIONONLINESURVEY
Letyourvoicebeheard!
PleaseparticipateintheTechnicalPublicationcustomersatisfactiononlinesurvey.
Thissurveytakeslessthanveminutestocompleteandyourresponseswillhelpexaminecurrentperformance
andidentifyareasforfutureimprovement.
Ourtoppriorityistoprovidetimely,accurate,anduserfriendlymanuals.
Theonlinesurveycanbefoundathttp://bit.ly/1w9uFMhorusingtheQRCodebelow.
_
OnlineSurveyQRCode
WARNING
•ReadSafetyonpage1-1beforeattemptinganyserviceonthevehicle.
•Beforeservicingvehicle,readcompletesection(s)andanyreferencedinformationthatmaybe
relevanttotheserviceorrepairtobeperformed.
NOTE:Thismanualrepresentsthemostcurrentinformationatthetimeofpublication.ClubCariscontinuallyworking
tofurtherimproveitsvehiclesandotherproducts.Theseimprovementsmayaffectservicingprocedures.
Anymodicationand/orsignicantchangeinspecicationsorprocedureswillbeforwardedtoallClubCar
dealersandwill,whenapplicable,appearinfutureeditionsofthismanual.
ClubCarreservestherighttochangespecicationsanddesignsatanytimewithoutnoticeandwithoutthe
obligationofmakingchangestounitspreviouslysold.
Therearenowarrantiesexpressedorimpliedinthismanual.Seethelimitedwarrantyfoundinthevehicle
Owner’sManual.

CONTENTS
SECTION1—Safety.........................................................................................................................................1-1
SafetyDetails................................................................................................................................................1-1
PersonalSafety.........................................................................................................................................1-1
MachineSafety..........................................................................................................................................1-1
Information................................................................................................................................................1-1
GeneralWarnings..........................................................................................................................................1-2
DisablingtheVehicle..................................................................................................................................1-3
DisconnectingtheBatteries–ElectricVehicles............................................................................................1-3
ConnectingtheBatteries–ElectricVehicles................................................................................................1-4
RecyclingLead-AcidBatteries....................................................................................................................1-4
Internationalsafetysymbolsonbatteries.....................................................................................................1-5
SECTION2—VehicleSpecications..................................................................................................................2-1
VehicleSpecications....................................................................................................................................2-1
VehicleSpecications................................................................................................................................2-1
QuiQBatteryChargerSpecications...........................................................................................................2-3
SECTION3—GeneralInformation.....................................................................................................................3-1
ModelIdentication........................................................................................................................................3-1
Storingthevehicle.........................................................................................................................................3-2
PreparingtheVehicleforExtendedStorage................................................................................................3-2
ReturningtheStoredVehicletoService......................................................................................................3-3
SECTION4—BodyandTrim............................................................................................................................4-1
CleaningtheVehicle......................................................................................................................................4-1
SeatCleaning............................................................................................................................................4-1
FrontBodyRepair.........................................................................................................................................4-2
LightScratches..........................................................................................................................................4-2
AbrasionsandHaze..................................................................................................................................4-2
LargeScratchesandAbrasions..................................................................................................................4-2
FrontBody....................................................................................................................................................4-2
BrushguardRemoval.................................................................................................................................4-2
BrushguardInstallation..............................................................................................................................4-3
CowlRemoval...........................................................................................................................................4-4
CowlInstallation........................................................................................................................................4-4
GrilleRemoval...........................................................................................................................................4-6
GrilleInstallation........................................................................................................................................4-6
FrontBumperandSideFenderRemoval....................................................................................................4-8
FrontBumperandSideFenderInstallation..................................................................................................4-8
InstrumentPanelRemoval.........................................................................................................................4-9
InstrumentPanelInstallation......................................................................................................................4-9
DashRemoval.........................................................................................................................................4-10
DashInstallation......................................................................................................................................4-10
TiltBed.......................................................................................................................................................4-12
TiltBedRemoval.....................................................................................................................................4-12
TiltBedInstallation..................................................................................................................................4-12
BedLatchAssemblyRemoval..................................................................................................................4-14
BedLatchAssemblyInstallation...............................................................................................................4-14
RearFendersandTailskirt............................................................................................................................4-16
RearFenderandTailskirtRemoval...........................................................................................................4-17
RearFenderandTailskirtInstallation........................................................................................................4-17
RearTriangleReector................................................................................................................................4-18
RearTriangleReectorRemoval..............................................................................................................4-18
RearTriangleReectorInstallation...........................................................................................................4-18
ElectricBedLift...........................................................................................................................................4-20
ElectricBedLiftRemoval.........................................................................................................................4-21
2019TransporterMaintenanceandServiceManualPageiii

ElectricBedLiftInstallation......................................................................................................................4-21
FloorMat....................................................................................................................................................4-22
FloorMatRemoval..................................................................................................................................4-22
FloorMatInstallation................................................................................................................................4-22
Rear-FacingSeat........................................................................................................................................4-23
TrailerHitch.................................................................................................................................................4-24
TrailerHitchRemoval...............................................................................................................................4-24
TrailerHitchInstallation............................................................................................................................4-24
ElectrolyteTray...........................................................................................................................................4-25
ElectrolyteTrayRemoval.........................................................................................................................4-26
ElectrolyteTrayInstallation.......................................................................................................................4-26
SECTION5—AcceleratorandBrakePedalGroup.............................................................................................5-1
BrakePedalandParkBrake..........................................................................................................................5-1
BrakePedalRemoval................................................................................................................................5-1
BrakePedalInstallation.............................................................................................................................5-2
ParkBrakeRemoval..................................................................................................................................5-4
ParkBrakeInstallation...............................................................................................................................5-5
AcceleratorPedal–ElectricVehicles..............................................................................................................5-6
AcceleratorPedalRemoval–ElectricVehicles............................................................................................5-7
AcceleratorPedalInstallation–ElectricVehicles.........................................................................................5-7
PedalGroupAdjustment–ElectricVehicles....................................................................................................5-8
SECTION6—BrakeSystem.............................................................................................................................6-1
GeneralInformation.......................................................................................................................................6-1
BrakeShoeRemoval.....................................................................................................................................6-1
BrakeAssemblyCleaning..............................................................................................................................6-3
BrakeShoeInstallation..................................................................................................................................6-6
BrakeAdjustment..........................................................................................................................................6-7
BrakeClusterAdjustment...........................................................................................................................6-8
BrakeCableEqualization.........................................................................................................................6-10
FinalBrakeClusterAdjustment..................................................................................................................6-11
TestDriveVehicle.....................................................................................................................................6-11
BrakeClusterRemovalandInstallation.........................................................................................................6-12
FrontBrakeClusterRemoval....................................................................................................................6-12
FrontBrakeClusterInstallation.................................................................................................................6-12
RearBrakeClusterRemoval....................................................................................................................6-14
RearBrakeClusterInstallation.................................................................................................................6-14
FrontBrakeCables......................................................................................................................................6-15
FrontBrakeCableRemoval.....................................................................................................................6-16
FrontBrakeCableInstallation...................................................................................................................6-16
RearBrakeCables......................................................................................................................................6-17
RearBrakeCableRemoval......................................................................................................................6-18
RearBrakeCableInstallation...................................................................................................................6-18
EmergencyBrakeSystem............................................................................................................................6-19
EmergencyBrakeRemoval......................................................................................................................6-19
EmergencyBrakeInstallation...................................................................................................................6-20
EmergencyBrakeAdjustment..................................................................................................................6-20
SECTION7—SteeringandFrontSuspension....................................................................................................7-1
GeneralInformation.......................................................................................................................................7-1
SteeringWheel..............................................................................................................................................7-1
SteeringWheelRemoval............................................................................................................................7-1
SteeringWheelInstallation.........................................................................................................................7-2
SteeringColumn............................................................................................................................................7-3
SteeringColumnRemoval..........................................................................................................................7-4
SteeringColumnDisassembly....................................................................................................................7-4
SteeringColumnAssembly........................................................................................................................7-4
SteeringColumnInstallation.......................................................................................................................7-5
SteeringAdjustment......................................................................................................................................7-6
RackandPinion............................................................................................................................................7-7
Pageiv2019TransporterMaintenanceandServiceManual

RackandPinionInspection........................................................................................................................7-7
RackandPinionRemoval..........................................................................................................................7-7
RackandPinionDisassembly....................................................................................................................7-8
RackandPinionAssembly.......................................................................................................................7-10
RackandPinionInstallation.....................................................................................................................7-13
TieRodandDragLink.................................................................................................................................7-14
TieRodandDragLinkRemoval...............................................................................................................7-14
TieRodandDragLinkInstallation............................................................................................................7-14
FrontSuspension........................................................................................................................................7-15
Lubrication..............................................................................................................................................7-15
WheelAlignment.....................................................................................................................................7-15
FrontSuspensionComponents.....................................................................................................................7-17
LeafSpringRemoval...............................................................................................................................7-17
LeafSpringInstallation.............................................................................................................................7-17
KingpinandSteeringSpindleRemoval.....................................................................................................7-17
KingpinandSteeringSpindleInstallation...................................................................................................7-20
DeltaA-PlateRemoval.............................................................................................................................7-20
DeltaA-PlateInstallation..........................................................................................................................7-20
ShockAbsorberRemoval.........................................................................................................................7-20
ShockAbsorberInstallation......................................................................................................................7-20
FrontWheelBearingsandHubs...................................................................................................................7-21
FrontWheelFreePlayInspection.............................................................................................................7-21
FrontHubandWheelBearingsRemoval...................................................................................................7-21
FrontHubandWheelBearingsInstallation................................................................................................7-22
SECTION8—WheelsandTires........................................................................................................................8-1
GeneralInformation.......................................................................................................................................8-1
Wheels.........................................................................................................................................................8-1
WheelRemoval.........................................................................................................................................8-1
WheelInstallation......................................................................................................................................8-1
Tires.............................................................................................................................................................8-2
TireRemoval.............................................................................................................................................8-2
TireRepair................................................................................................................................................8-2
TireInstallation..........................................................................................................................................8-3
SECTION9—RearSuspension........................................................................................................................9-1
GeneralInformation.......................................................................................................................................9-1
ShockAbsorbers...........................................................................................................................................9-1
ShockAbsorberInspectionandRemoval...................................................................................................9-1
ShockAbsorberInstallation........................................................................................................................9-1
Multi-LeafSprings..........................................................................................................................................9-2
Multi-LeafSpringRemoval.........................................................................................................................9-2
Multi-LeafSpringInstallation......................................................................................................................9-3
SECTION10—PeriodicMaintenance..............................................................................................................10-1
GeneralInformation.....................................................................................................................................10-1
Pre-OperationandDailySafetyChecklist......................................................................................................10-1
PerformanceInspection...........................................................................................................................10-1
Maintenance...............................................................................................................................................10-2
PeriodicServiceSchedules..........................................................................................................................10-3
PeriodicLubricationSchedules.....................................................................................................................10-6
SECTION11—ControllerDiagnosticT ool(CDT)...............................................................................................11-1
GeneralInformation......................................................................................................................................11-2
Features..................................................................................................................................................11-2
PluggingtheCDTintotheVehicle..................................................................................................................11-2
IntroductoryDisplay..................................................................................................................................11-3
QuickReferenceGuide–IQPluswithQuiqCharger......................................................................................11-4
SystemInfo..................................................................................................................................................11-5
ModelNumber..........................................................................................................................................11-5
2019TransporterMaintenanceandServiceManualPagev

SerialNumber..........................................................................................................................................11-5
HardwareVersion.....................................................................................................................................11-5
ProtocolVersion.......................................................................................................................................11-5
ParamBlockVersion.................................................................................................................................11-5
MFGDateCode.......................................................................................................................................11-5
OSVersion...............................................................................................................................................11-5
SMVersion..............................................................................................................................................11-5
VCLAppVersion......................................................................................................................................11-5
Parameters..................................................................................................................................................11-6
Settings...................................................................................................................................................11-6
AmpHours...............................................................................................................................................11-9
AccessCodes..........................................................................................................................................11-9
VehicleID................................................................................................................................................11-9
MonitorMenu.............................................................................................................................................11-11
SpeedIn................................................................................................................................................11-11
Throttle%..............................................................................................................................................11-11
BattVoltage............................................................................................................................................11-11
HeatsinkTemp.......................................................................................................................................11-11
Mode.....................................................................................................................................................11-11
ArmCurrent...........................................................................................................................................11-11
FieldCurrent..........................................................................................................................................11-11
ArmPWM..............................................................................................................................................11-12
FieldPWM.............................................................................................................................................11-12
FootInput..............................................................................................................................................11-12
KeyInput...............................................................................................................................................11-12
ForwardInput.........................................................................................................................................11-12
ReverseInput.........................................................................................................................................11-12
ModeSwitch..........................................................................................................................................11-12
WKAwayRelay......................................................................................................................................11-12
MainCont..............................................................................................................................................11-12
PasswordTries(OEMAccessLevelOnly)................................................................................................11-12
CirBRKROpen#...................................................................................................................................11-13
THRTLFault#........................................................................................................................................11-13
Undervoltage#.......................................................................................................................................11-13
Overvoltage#.........................................................................................................................................11-13
TempCutback#.....................................................................................................................................11-13
HPD#....................................................................................................................................................11-13
MainWelded#.......................................................................................................................................11-13
RelayWelded#......................................................................................................................................11-13
SPDSensor#........................................................................................................................................11-13
MainDRVOn#......................................................................................................................................11-13
MainCoilOPN#.....................................................................................................................................11-13
MainDropout#.......................................................................................................................................11-13
MotorStall#...........................................................................................................................................11-13
MainDRVROff#.....................................................................................................................................11-13
RelayDNC#..........................................................................................................................................11-14
CurrentSense#.....................................................................................................................................11-14
M-Shorted#...........................................................................................................................................11-14
RelayCoil#............................................................................................................................................11-14
Precharge#...........................................................................................................................................11-14
FLDMissing#........................................................................................................................................11-14
HWFailsafe#.........................................................................................................................................11-14
DRVROvercur#.....................................................................................................................................11-14
RLYDRVROn#.....................................................................................................................................11-14
RLYDRVROff#.....................................................................................................................................11-14
VminI...................................................................................................................................................11-14
SignedBatteryCurrent............................................................................................................................11-14
BDIPercent............................................................................................................................................11-14
ChargerInhibit........................................................................................................................................11-15
LEDDriver.............................................................................................................................................11-15
Odometer...............................................................................................................................................11-15
BDIInfo.................................................................................................................................................11-15
BatteryMonitor.......................................................................................................................................11-15
ChargingTotals......................................................................................................................................11-15
Pagevi2019TransporterMaintenanceandServiceManual

AmpHoursDisplay.................................................................................................................................11-16
LIN........................................................................................................................................................11-16
DiagnosticsMenu.......................................................................................................................................11-17
PresentErrorsFolder..............................................................................................................................11-17
FaultHistoryFolder................................................................................................................................11-17
SystemFaults........................................................................................................................................11-17
FaultRecovery.......................................................................................................................................11-19
FaultDescriptions.......................................................................................................................................11-20
01ThrottleFault1..................................................................................................................................11-20
02LowBatteryVoltage...........................................................................................................................11-20
03Overvoltage.......................................................................................................................................11-20
04ThermalCutback...............................................................................................................................11-20
06HPD..................................................................................................................................................11-20
07MainWelded.....................................................................................................................................11-20
08RelayWelded....................................................................................................................................11-20
09SpeedSensor....................................................................................................................................11-20
10MainDriverOn..................................................................................................................................11-20
11MainCoilOpen..................................................................................................................................11-20
12MainDropout.....................................................................................................................................11-21
13MotorStall.........................................................................................................................................11-21
14MainDriverOff...................................................................................................................................11-21
15RelayDNC........................................................................................................................................11-21
16KeyswitchSRO..................................................................................................................................11-21
17CurrentSense...................................................................................................................................11-21
18M-Shorted........................................................................................................................................11-21
20DriverOvercurrent.............................................................................................................................11-21
21PrechargeFault.................................................................................................................................11-21
22FieldMissing.....................................................................................................................................11-21
23RelayDriverOn.................................................................................................................................11-21
24HWFailsafe.......................................................................................................................................11-21
25IncorrectPassword............................................................................................................................11-22
26CircuitBRKROpen............................................................................................................................11-22
27MaxPasswordTries...........................................................................................................................11-22
29RelayDRVROff.................................................................................................................................11-22
30RelayCoilFault.................................................................................................................................11-22
Anti-TamperFault...................................................................................................................................11-22
LockoutFault.........................................................................................................................................11-22
LowSOC...............................................................................................................................................11-22
MainCONTDNC....................................................................................................................................11-23
MainCoilFault.......................................................................................................................................11-23
PROC/Wiring.........................................................................................................................................11-23
OpenArmature.......................................................................................................................................11-23
IncorrectPassword(OEMAccessLevelOnly)..........................................................................................11-23
FaultHistory...........................................................................................................................................11-23
ClearingFaultHistory.............................................................................................................................11-23
Programming.............................................................................................................................................11-24
Cloning..................................................................................................................................................11-24
Favorites....................................................................................................................................................11-24
HHPSettings.............................................................................................................................................11-25
Plot&Log..................................................................................................................................................11-26
Plot........................................................................................................................................................11-26
Log........................................................................................................................................................11-26
CDTTroubleshooting..................................................................................................................................11-27
ConnectionTests........................................................................................................................................11-28
SECTION12—ElectricalSystemTroubleshooting............................................................................................12-1
GeneralInformation.....................................................................................................................................12-1
Accessories.............................................................................................................................................12-1
ChargeIndicatorLight..............................................................................................................................12-1
Features.................................................................................................................................................12-1
SonicWeld,Diode,and10kOhmResistorLocations.....................................................................................12-4
Troubleshooting...........................................................................................................................................12-5
TroubleshootingtheVehiclewiththeCDT.................................................................................................12-5
2019TransporterMaintenanceandServiceManualPagevii

TroubleshootingGuide1..........................................................................................................................12-6
TroubleshootingGuide2..........................................................................................................................12-9
TestProcedures.........................................................................................................................................12-11
TestingBasics........................................................................................................................................12-11
SECTION13—ElectricalComponents.............................................................................................................13-1
KeySwitch..................................................................................................................................................13-1
TestingtheKeySwitch.............................................................................................................................13-1
KeySwitchRemoval................................................................................................................................13-1
KeySwitchInstallation.............................................................................................................................13-1
Forward/ReverseRockerSwitch...................................................................................................................13-2
Forward/ReverseRockerSwitchRemoval.................................................................................................13-2
Forward/ReverseRockerSwitchInstallation..............................................................................................13-2
Run/TowSwitch...........................................................................................................................................13-3
Run/TowSwitchRemoval.........................................................................................................................13-3
Run/TowSwitchInstallation......................................................................................................................13-3
CircuitBreaker............................................................................................................................................13-4
CircuitBreakerRemoval..........................................................................................................................13-4
CircuitBreakerInstallation........................................................................................................................13-4
MotorControllerOutputRegulator(MCOR)...................................................................................................13-5
TestingtheMCOR...................................................................................................................................13-5
MCORRemoval......................................................................................................................................13-5
MCORInstallation...................................................................................................................................13-5
ReverseBuzzer...........................................................................................................................................13-6
ReverseBuzzerRemoval.........................................................................................................................13-6
ReverseBuzzerInstallation......................................................................................................................13-6
SpeedControllerCover................................................................................................................................13-6
RemovingtheSpeedControllerCover......................................................................................................13-6
InstallingtheSpeedControllerCover........................................................................................................13-6
Solenoid......................................................................................................................................................13-7
SolenoidRemoval...................................................................................................................................13-7
SolenoidInstallation.................................................................................................................................13-7
SpeedController.........................................................................................................................................13-8
SpeedControllerRemoval.......................................................................................................................13-8
SpeedControllerInstallation.....................................................................................................................13-8
ChargeIndicatorLight.................................................................................................................................13-10
TestingtheChargeIndicatorLight............................................................................................................13-10
ChargeIndicatorLightRemoval...............................................................................................................13-10
ChargeIndicatorLightInstallation............................................................................................................13-10
EmergencyStopSwitch..............................................................................................................................13-10
TestingtheEmergencyStopSwitch.........................................................................................................13-10
EmergencyStopSwitchRemoval............................................................................................................13-10
EmergencyStopSwitchInstallation.........................................................................................................13-11
Headlights..................................................................................................................................................13-12
HeadlightBezelRemoval........................................................................................................................13-12
HeadlightBezelInstallation.....................................................................................................................13-12
HalogenHeadlightBulbRemoval............................................................................................................13-13
HalogenHeadlightBulbInstallation..........................................................................................................13-13
HalogenHeadlightLensRemoval............................................................................................................13-14
HalogenHeadlightLensInstallation.........................................................................................................13-14
LEDHeadlightRemoval..........................................................................................................................13-15
LEDHeadlightInstallation.......................................................................................................................13-15
LockoutRelay............................................................................................................................................13-15
LockoutRelayRemoval..........................................................................................................................13-16
LockoutRelayInstallation........................................................................................................................13-16
WalkAwayRelay........................................................................................................................................13-17
WalkAwayRelayRemoval......................................................................................................................13-17
WalkAwayRelayInstallation...................................................................................................................13-17
SECTION14—Batteries.................................................................................................................................14-1
GeneralInformation.....................................................................................................................................14-1
BatteryTestingBasics–6Volt......................................................................................................................14-2
Pageviii2019TransporterMaintenanceandServiceManual

Observation.............................................................................................................................................14-2
MeasuringVoltageofBatterySet..............................................................................................................14-2
BatteryCellNumbering............................................................................................................................14-2
BatteryTesting–6Volt................................................................................................................................14-3
BatteryRegrouping......................................................................................................................................14-3
BatteryReplacement...................................................................................................................................14-5
BatteryCare................................................................................................................................................14-6
WaterQuality..........................................................................................................................................14-6
Deionizer................................................................................................................................................14-7
BatteryCare–VehiclesEquippedwiththeSingle-PointWateringSystem(SPWS)......................................14-8
BatteryCare–VehiclesWithouttheSingle-PointWateringSystem(SPWS)................................................14-9
Self-Discharge........................................................................................................................................14-10
ElectrolyteLevel.....................................................................................................................................14-10
VibrationDamage...................................................................................................................................14-11
SinglePointWateringSystem(SPWS).........................................................................................................14-11
InitialMaintenanceoftheSPWS..............................................................................................................14-11
WateringBatterieswiththeSPWS...........................................................................................................14-11
BatteryStorage..........................................................................................................................................14-13
FleetRotation.............................................................................................................................................14-13
Deep-Discharge.........................................................................................................................................14-14
EarlyExcessiveDischarging.......................................................................................................................14-14
SECTION15—BatteryCharger.......................................................................................................................15-1
GeneralInformation.....................................................................................................................................15-1
Features.................................................................................................................................................15-1
ULandCSAListing.................................................................................................................................15-1
CECompliance.......................................................................................................................................15-1
IP(IngressProtection)Rating...................................................................................................................15-1
HowToIdentifyChargeAlgorithmNumber................................................................................................15-2
HowToChangeTheAlgorithm.................................................................................................................15-3
TheChargeCircuit...................................................................................................................................15-3
OnboardChargerOperation.........................................................................................................................15-4
ChargerDisplays.....................................................................................................................................15-6
ACPowerConnection..............................................................................................................................15-8
ChargingBatteries...................................................................................................................................15-8
Maintenance...............................................................................................................................................15-9
Troubleshooting..........................................................................................................................................15-10
TestProcedures.........................................................................................................................................15-11
ChargerRepairs.........................................................................................................................................15-12
OnboardChargerRemovalAndInstallation..................................................................................................15-12
OnboardChargerRemoval.....................................................................................................................15-12
OnboardChargerInstallation...................................................................................................................15-13
SECTION16—Motor......................................................................................................................................16-1
GeneralInformation.....................................................................................................................................16-1
ExternalMotorTesting.................................................................................................................................16-1
MotorRemoval............................................................................................................................................16-3
MotorDisassembly......................................................................................................................................16-5
MotorComponentTestingandInspection......................................................................................................16-7
ArmatureInspectionandTesting...............................................................................................................16-7
MotorFrameandFieldWindingsInspection..............................................................................................16-8
MotorBrush,Spring,andTerminalInsulatorInspection..............................................................................16-8
ReconditioningtheMotor............................................................................................................................16-11
MotorSpecications...............................................................................................................................16-11
MotorAssembly..........................................................................................................................................16-11
MotorInstallation........................................................................................................................................16-13
SECTION17—Transaxle................................................................................................................................17-1
Lubrication..................................................................................................................................................17-1
AxleBearingandShaft................................................................................................................................17-1
AxleShaft...............................................................................................................................................17-1
2019TransporterMaintenanceandServiceManualPageix

AxleBearing............................................................................................................................................17-4
Transaxle....................................................................................................................................................17-5
TransaxleRemoval..................................................................................................................................17-5
TransaxleDisassembly,Inspection,andAssembly.........................................................................................17-8
TransaxleDisassemblyandInspection......................................................................................................17-8
TransaxleAssembly................................................................................................................................17-10
TransaxleInstallation..................................................................................................................................17-11
SECTION18—WiringDiagrams......................................................................................................................18-1
GeneralInformation.....................................................................................................................................18-1
Index..........................................................................................................................................................Index-1
Pagex2019TransporterMaintenanceandServiceManual

SECTION1—SAFETY1
Safety
SAFETYDETAILS
ToensurethesafetyofthoseservicingClubCarvehicles,andtoprotectthevehiclesfrompossibledamageresulting
fromimproperserviceormaintenance,theproceduresinthismanualmustbefollowed.
ItisimportanttonotethatthroughoutthismanualtherearestatementslabeledDANGER,WARNING,orCAUTION.
Thesespecialstatementsrelatetospecicsafetyissues,andmustberead,understood,andheededbefore
proceedingwithprocedures.TherearestatementslabeledNOTE,whichprovideotheressentialserviceor
maintenanceinformation.
PERSONALSAFETY
DANGER
•ADANGERindicatesanimmediatehazardthatwillresultinseverepersonalinjuryordeath.The
colorassociatedwithDangerisRED.
WARNING
•AWARNINGindicatesanimmediatehazardthatcouldresultinseverepersonalinjuryordeath.
ThecolorassociatedwithWarningisORANGE.
CAUTION
•ACAUTIONwiththesafetyalertsymbolindicatesahazardorunsafepracticethatcouldresultin
minorpersonalinjury.ThecolorassociatedwithCautionisYELLOW.
MACHINESAFETY
CAUTION
•ACAUTIONwithoutthesafetyalertsymbolindicatesapotentiallyhazardoussituationthatcould
resultinpropertydamage.
ACAUTION,withoutthesafetyalertsymbol,isintendedformachineandpropertysafety.Itisusedthroughoutthis
manualfollowedbyspecicinstructionstopreventmachineorpropertydamage.FailuretofollowtheseCAUTION
messagescouldresultinmachineorpropertydamage.
INFORMATION
NOTE:Instructionsthatclarifysteps,procedures,orotherinformationinthismanual.
2019TransporterMaintenanceandServiceManualPage1-1

1GeneralWarningsSAFETY
GENERALWARNINGS
Thefollowingsafetystatementsmustbeheededwheneverthevehicleisbeingoperated,repaired,orserviced.Other
specicsafetystatementsappearthroughoutthismanualandonthevehicle.
DANGER
•Battery–Explosivegases!Donotsmoke.Keepsparksandamesawayfromthevehicleandservice
area.Ventilatewhenchargingoroperatingvehicleinanenclosedarea.Wearafullfaceshieldand
rubbergloveswhenworkingonornearbatteries.
•Thevehiclewillnotprovideprotectionfromlightning,yingobjects,orotherstorm-relatedhazards.If
caughtinastormwhiledrivingaClubCarvehicle,exitthevehicleandseekshelterinaccordancewith
applicablesafetyguidelinesforyourlocation.
WARNING
•Followtheproceduresexactlyasstatedinthismanual,andheedallDANGER,WARNING,and
CAUTIONstatementsinthismanualaswellasthoseonthevehicleandbatterycharger.
•Donotleavechildrenunattendedinvehicleatanytime.
•Priortoleavingthevehicleunattendedorservicingthevehicle,settheparkbrake,placethe
Forward/ReversehandleorswitchintheNEUTRALposition,turnthekeyswitchtotheOFFposition,
andremovethekey.Chockthewheelswhenservicingthevehicle.
•Improperuseofthevehicleorfailuretoproperlymaintainitcanresultindecreasedvehicle
performance,severepersonalinjury,ordeath.
•Anymodicationorchangetothevehiclethataffectstheelectricalsystem,stabilityorhandlingof
thevehicle,orincreasesmaximumvehiclespeedbeyondfactoryspecications,canresultinsevere
personalinjuryordeath.
•Checkthevehicleforproperlocationofallvehiclesafetyandoperationdecalsandmakesuretheyare
inplaceandareeasytoread.
•Forvehicleswithcargobeds,removeallcargo(includingaccessories)beforeraisingthebedor
servicingthevehicle.Ifthevehicleisequippedwithaproprod,ensurethatitissecurelyengaged
whilebedisraised.Donotclosebeduntilallpersonsareclearofcargobedarea.Keephandsclearof
allcrushareas.Donotdropcargobed;lowergentlyandkeepentirebodyclear.Failuretoheedthis
warningcanresultinseverepersonalinjuryordeath.
•Onlytrainedtechniciansshouldserviceorrepairthevehicleorbatterycharger.Anyonedoingeven
simplerepairsorserviceshouldhaveknowledgeandexperienceinelectricalandmechanicalrepair.
Theappropriateinstructionsmustbeusedwhenperformingmaintenance,service,oraccessory
installation.
•Ensurebatteryconnectionsarecleanandproperlytightened.SeeBatteryCare–VehiclesEquipped
withtheSingle-PointWateringSystem(SPWS)onpage14-8orBatteryCare–VehiclesWithoutthe
Single-PointWateringSystem(SPWS)onpage14-9.
•PlaceRun/TowswitchintheTOWpositionbeforedisconnectingorconnectingthebatteries.Failureto
heedthiswarningcanresultinabatteryexplosionorseverepersonalinjury.
•Toavoidunintentionallystartinganelectricvehicle,disconnectthebatteriesanddischargethe
controller.SeeDisconnectingtheBatteries–ElectricVehiclesonpage1-3.
WARNINGCONTINUEDONNEXTPAGE
Page1-22019TransporterMaintenanceandServiceManual

SAFETYGeneralWarnings1
WARNING
•Wearsafetyglassesorapprovedeyeprotectionwhenservicingthevehicleorbatterycharger.Weara
fullfaceshieldandrubbergloveswhenworkingonornearbatteries.
•Donotwearlooseclothingorjewelrysuchasrings,watches,chains,etc.,whenservicingthe
vehicleorbatterycharger.
•Useinsulatedtoolswhenworkingnearbatteriesorelectricalconnections.Useextremecautionto
avoidshortingofcomponentsorwiring.
DISABLINGTHEVEHICLE
1.Engageparkbraketolockwheels.
2.TurnthekeyswitchOFFandremovethekey.
3.PlacetheForward/ReversecontrolintheNEUTRALposition.
4.Inaddition,chockthewheelsifservicingorrepairingthevehicle.
DISCONNECTINGTHEBATTERIES–ELECTRICVEHICLES
1.Disablethevehicle.SeeDisablingtheVehicleonpage1-3.
2.PlaceRun/TowswitchintheTOWpositionbeforedisconnectingorconnectingthebatteries.Failuretoheed
thiswarningcanresultinabatteryexplosionorseverepersonalinjury.
3.Disconnectthebatteries,negative(–)cablerst,asshown(Figure1-1).
4.Afterdisconnectingthebatteries,wait90secondsforthecontrollercapacitorstodischarge.
(Viewedfromdriversideofvehicle)
1.PlaceRun/T owSwitchinTOWbeforedisconnectingor
connectingbatterycables.
2.Removenegativebatterycable.
3.Removepositivebatterycable.
Connectbatterycablesinreverseorder.
2780
Figure1-1BatteryCableRemoval–ElectricVehicle
2019TransporterMaintenanceandServiceManualPage1-3

1GeneralWarningsSAFETY
CONNECTINGTHEBATTERIES–ELECTRICVEHICLES
1.EnsuretheRun/TowswitchisintheTOWposition.
2.Connectthebatterycables,positive(+)cablerst.
3.Tightenbatteryterminalsto110in·lb(12.4N·m).
4.CoatterminalswithBatteryT erminalProtectorSpraytominimizecorrosion.
RECYCLINGLEAD-ACIDBATTERIES
WARNING
•Lead-acidbatteriescontainlead(Pb),othermetals,acidsandothercompounds.Ifimproperlyhandled,
theycancontaminatebothwaterandsoil,causingenvironmentaldamageandpersonalinjury.
Lead-acidbatteriesareidentiedbythesymbolshownbelowandshouldbeproperlyrecycled(Figure1-2).They
cannotbedisposedasmunicipalwasteandmustbecollectedseparately.Responsibilityforenvironmentalprotection
mustbeshared,notonlybythemanufacturersofthebatteries,butbypeoplewhousethebatteriesaswell.Please
contactyournearestClubCardealerordistributorforinformationonhowtoproperlyrecycleyourbatteries.
1403
Figure1-2DisposeofLead-acidBatteriesProperly
Page1-42019TransporterMaintenanceandServiceManual

SAFETYGeneralWarnings1
INTERNATIONALSAFETYSYMBOLSONBATTERIES
Anyoneusing,repairing,orservicingthevehiclemustunderstandandheedthesafetysymbolsonthevehiclebattery
orbatteries.
_
1.Shieldeyes.3.Nosmoking,noopenames,nosparks.5.Batteryacidhazard.
2.Readandfollowoperatinginstructions.4.Keepawayfromchildren.6.Explosivegashazard.
RefertoGeneralWarningsformoreinformation.
1642
Figure1-3InternationalSafetySymbolsonBatteries
2019TransporterMaintenanceandServiceManualPage1-5

PaginationPage
1GeneralWarningsSAFETY
Page1-62019TransporterMaintenanceandServiceManual

SECTION2—VEHICLESPECIFICATIONS2
VehicleSpecications
VEHICLESPECIFICATIONS
VEHICLESPECIFICATIONS
_
SPECIFICATIONSTRANSPORTER
POWERSOURCE
Drivemotor:Directdrive,48voltsDC,shuntwound,3.1hp●
Transaxle:Doublereductionhelicalgearwith12.28:1directdriveaxle●
Electricalsystem:48voltsDC,reducedspeedreverse●
Batteries:Highcapacity,deepcycle●
Charger:Automatic,13.5amp;ULandCSAlisted.SeeQuiQBatteryChargerSpecicationsonpage2-3.●
STEERING/SUSPENSION/BRAKES
Steering:Self-adjustingrackandpinion●
Suspension:Independentleafspringwithdualhydraulicshocks●
Brakes:Mechanicalbrakecablesystemtomanuallyadjusteddrumbrakesoneachwheel.Parkbrakeis
automaticallyreleased.Multi-latchratchetandpawl●
BODY/CHASSIS
Frame/chassis:TwinI-Beamweldedaluminum●
Sideandrearbody:Allaluminum●
Frontbody:ArmorFlex®●
Frontbodynish:Automotive-gradepaintwithclear-coatnish●
Tires:20x10–10tubeless,6-plyratedloadrangefrontandrear●
DIMENSIONS/WEIGHT
Overalllength:Standardrearcover
withrearseat*:
*Add1.8in(4.5cm)forheavy-dutyfrontbumper
140.6in(357.2cm)
146.9in(373.0cm)
Overallwidth:Withoutmirrors
Withmirrors
50.3in(127.7cm)
62.6in(159.0cm)
Overallheight:Atsteeringwheel
Withcanopy
Withcab
47.1in(119.6cm)
70.7in(179.5cm)
74.3in(188.7cm)
Wheelbase99.1in(251.7cm)
Groundclearance5.2in(13.2cm)
Frontwheeltread36.6in(92.9cm)
Rearwheeltread39.5in(100.3cm)
Weight:Standardelectricvehicle1413lb(641kg)
Forwardspeed15to17mph(24to27km/h)
Outsideclearancecircle(diameter)340.5in(864.9cm)
Turningradius(perSAEJ695)162.8in(413.4cm)
TABLECONTINUEDONNEXTPAGE
2019TransporterMaintenanceandServiceManualPage2-1