Club Car 1998 DS Manual

Manual Number 101968405
Edition Code 0299C1208B
PowerDrive Plus Vehicles
1998-1999
Maintenance and
Service Manual
Supplement

1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page i
FOREWORD
The Club Car PowerDrive Plus electric vehicle is engineered and built to provide the ultimate in performance
efficiency. However, timely and appropriate vehicle maintenance and repair is essential for long-term vehicle
performance and continued safe and reliable service.
This supplement provides detailed information for the maintenance and repair of PowerDrive Plus electric
vehicles and should be used in conjunction with the 1998/1999 DS Golf Car Maintenance and Service Man-
ual, Publication Part No. 101968401. If you do not have the 1998/1999 DS Golf Car Maintenance and Service
Manual, you may order one from your local Club Car representative.
This supplement and the 1998/1999 DS Golf Car Maintenance and Service Manual should be thoroughly
reviewed prior to servicing the vehicle. 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 basic knowledge and skills in
electrical and mechanical repair. If the technician does not have such basic knowledge and skills, attempted
service or repairs to the vehicle may render the vehicle unsafe. For this reason, Club Car advises all repairs
and/or service be performed by an authorized Club Car distributor/dealer representative or by a Club Car fac-
tory trained technician.
This service supplement, along with the appropriate Maintenance and Service Manual, covers all aspects of
typical service requirements for the PowerDrive Plus electric vehicle. If you need additional information, you
may write to us at: Club Car, Inc.; P.O. Box 204658; Augusta, GA 30917 or contact a Club Car technical ser-
vice representative at [phone], ext. 3580.
©1999 Club Car, Inc.
Club Car, PowerDrive, PowerDrive Plus,
are registered trademarks of Club Car, Inc.
This manual effective August 18, 1997

Page ii 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement
•READ SECTION 1–SAFETY IN THE MAINTENANCE AND SERVICE MANUAL BEFORE
ATTEMPTING ANY SERVICE ON THIS VEHICLE.
•BEFORE SERVICING VEHICLE, READ COMPLETE SECTION(S) AND ANY REFERENCED
INFORMATION RELEVANT TO SERVICE OR REPAIR TO BE PERFORMED.
•THIS MANUAL REPRESENTS THE MOST CURRENT INFORMATION AT THE TIME OF
PUBLICATION. CLUB CAR, INC. IS CONTINUALLY WORKING TO FURTHER IMPROVE OUR
VEHICLES AND OTHER PRODUCTS. THESE IMPROVEMENTS MAY AFFECT SERVICING
PROCEDURES. ANY MODIFICATION AND/OR SIGNIFICANT CHANGE IN SPECIFICATIONS OR
PROCEDURES WILL BE FORWARDED TO ALL CLUB CAR DISTRIBUTORS AND 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, OVERLOADING, ABUSE,
OR NEGLECT (INCLUDING FAILURE TO PROVIDE REASONABLE OR NECESSARY
MAINTENANCE AS INSTRUCTED IN THE VEHICLE OWNER’S MANUAL), ACCIDENT OR
ALTERATION, INCLUDING INCREASING VEHICLE SPEED BEYOND FACTORY
SPECIFICATIONS OR MODIFICATIONS WHICH AFFECT THE STABILITY OF THE VEHICLE OR
THE OPERATION THEREOF, WILL VOID THE WARRANTY.
•CLUB CAR, INC. RESERVES THE RIGHT TO CHANGE SPECIFICATIONS AND DESIGNS AT
ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION OR LIABILITY
WHATSOEVER.
•THERE ARE NO WARRANTIES EXPRESSED OR IMPLIED IN THIS MANUAL. SEE THE LIMITED
WARRANTY FOUND IN THE VEHICLE OWNER’S MANUAL OR WRITE TO CLUB CAR, INC.
WARNING
NOTE

1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page iii
SECTION 10–PERIODIC MAINTENANCE
General Information .......................................................................................................................... 10-1
Daily Pre-Operation Safety Checklist ............................................................................................... 10-2
Periodic Service Schedule ............................................................................................................. 10-3
Lubrication ........................................................................................................................................ 10-4
Vehicle Capacities ............................................................................................................................ 10-4
SECTION 11–ELECTRICAL SYSTEM AND TESTING
General Information .......................................................................................................................... 11-1
Electrical Circuits .............................................................................................................................. 11-4
The Control Circuit ......................................................................................................................................... 11-4
The Power Circuit .......................................................................................................................................... 11-7
Electric Motor ................................................................................................................................................. 11-10
The Charge Circuit ......................................................................................................................................... 11-10
Index of Test Procedures .................................................................................................................. 11-11
Diagnostic Flow Charts ..................................................................................................................... 11-11
Test Procedures ............................................................................................................................... 11-14
The Communication Display Module (CDM) .................................................................................... 11-22
Using The Cdm To Retrieve Data From The Onboard Computer ................................................................. 11-23
CDM Troubleshooting Guide ............................................................................................................ 11-24
SECTION 12–ELECTRICAL COMPONENTS
Key Switch ........................................................................................................................................ 12-2
Forward/Reverse (F&R) Rocker Switch ............................................................................................12-3
Accelerator Pedal Limit Switch ......................................................................................................... 12-4
Reverse Buzzer ................................................................................................................................ 12-5
Main Solenoid ................................................................................................................................... 12-5
Dynamic Braking Solenoid ................................................................................................................ 12-6
Onboard Computer (OBC) ................................................................................................................ 12-7
Solid State Speed Controller ............................................................................................................ 12-9
Charger Receptacle Assembly ......................................................................................................... 12-9
Receptacle Fuse Link .................................................................................................................................... 12-10
Multi-step Potentiometer ................................................................................................................... 12-11
Multi-step Potentiometer Arm Adjustment ..................................................................................................... 12-13
Multi-step Potentiometer Arm Brush Replacement ........................................................................................ 12-14
Multi-step Potentiometer Adjustment ............................................................................................................. 12-15
Resistors ........................................................................................................................................................ 12-15
Battery Warning Light ....................................................................................................................... 12-16
Energy Displacement Module ........................................................................................................... 12-18
Tow/Run Switch ................................................................................................................................ 12-19

Page iv 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement
SECTION 13–BATTERIES
General Information ......................................................................................................................... 13-1
Common Misconceptions About Batteries ....................................................................................... 13-3
Replacing Batteries .......................................................................................................................... 13-4
Battery Care ..................................................................................................................................... 13-5
Preventive Maintenance ................................................................................................................................ 13-5
Self-Discharge ............................................................................................................................................... 13-5
Electrolyte Level ............................................................................................................................................ 13-5
Mineral Content ............................................................................................................................................. 13-6
Vibration Damage ......................................................................................................................................... 13-6
Battery Charging .............................................................................................................................. 13-6
General Information ...................................................................................................................................... 13-6
Charger Shuts Off After 16 Hours ................................................................................................................. 13-7
Deep Discharge ............................................................................................................................................ 13-7
Early Excessive Discharging ......................................................................................................................... 13-7
Incoming AC Service ..................................................................................................................................... 13-7
Fleet 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 Examples ............................................................................................................... 13-13
Battery Storage ................................................................................................................................ 13-14
Charging Battery Pack With Low Voltage ........................................................................................ 13-14
SECTION 14–POWERDRIVE BATTERY CHARGER
General Information ......................................................................................................................... 14-1
PowerDrive Charging Features ..................................................................................................................... 14-2
Battery Warning Light .................................................................................................................................... 14-3
The Charge Circuit ........................................................................................................................... 14-3
Charger Installation and Use ............................................................................................................ 14-3
Checking Battery Condition After A Charge Cycle ........................................................................... 14-7
Start Charge Cycle ........................................................................................................................................ 14-7
Troubleshooting ............................................................................................................................... 14-8
Troubleshooting Guide ............................................................................................................................. 14-9
Test Procedures ............................................................................................................................... 14-12
General ......................................................................................................................................................... 14-12
Plug and Cord Replacement ............................................................................................................ 14-20
Charger Cord and Plug Replacement ........................................................................................................... 14-20

1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page v
Charger Repairs ............................................................................................................................... 14-21
Heat Sink Assembly ....................................................................................................................................... 14-21
Transformer ................................................................................................................................................... 14-22
Ammeter ........................................................................................................................................................ 14-22
Fuse Link ....................................................................................................................................................... 14-23
Voltage Suppressor ....................................................................................................................................... 14-23
Charger Relay ................................................................................................................................................ 14-24
Charger AC Circuit Breaker ........................................................................................................................... 14-25
Charger AC Cord ........................................................................................................................................... 14-25
SECTION 15–MOTOR
General Information .......................................................................................................................... 15-1
External Motor Testing ...................................................................................................................... 15-2
Motor ................................................................................................................................................. 15-3
Testing and Inspecting Individual 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 Installation .............................................................................................................................. 15-12
Motor Speed Sensor ......................................................................................................................... 15-12
SECTION 16–TRANSAXLE
General Information .......................................................................................................................... 16-2
Lubrication ........................................................................................................................................ 16-2
Axle Shaft and Bearing ..................................................................................................................... 16-2
Axle Shaft ....................................................................................................................................................... 16-2
Axle Bearing ................................................................................................................................................... 16-6
Transaxle .......................................................................................................................................... 16-8
Transaxle Removal ........................................................................................................................................ 16-8
Transaxle Disassembly, Inspection and Assembly ........................................................................... 16-10
Transaxle Disassembly and Inspection ......................................................................................................... 16-10
Transaxle Assembly ....................................................................................................................................... 16-12
Shimming the Transaxle ................................................................................................................................ 16-14
Transaxle Installation ........................................................................................................................ 16-14

Page vi 1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement

1998/1999 PowerDrive Plus Vehicle Maintenance and Service Supplement Page 10-1
10
SECTION 10–PERIODIC MAINTENANCE
GENERAL INFORMATION
To ensure continued reliable performance of the PowerDrive Plus vehicle, a Preventive Maintenance program
should be established and followed. Preventive maintenance consists of the regular performance of scheduled
vehicle service and maintenance procedures, and is the only way to ensure the vehicle provides the safe, reliable,
and economical service it is designed to deliver. The following charts provide recommended service intervals for the
lubrication and maintenance of the PowerDrive Plus vehicle. Note that critical areas such as brake operation, accel-
erator operation, steering and tires should be performed daily. These checks can easily be performed when moving
the vehicle from the storage facility to the starting line. Any vehicle that is not functioning properly should be
removed from service until it has been repaired.
•IF ANY PROBLEMS ARE FOUND DURING SCHEDULED INSPECTION OR SERVICE, DO NOT OPERATE THE VEHICLE
UNTIL REPAIRS ARE MADE. FAILURE TO MAKE NECESSARY REPAIRS COULD RESULT IN FIRE, PROPERTY DAMAGE,
SEVERE PERSONAL INJURY, OR DEATH.
•ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE. WEAR A FULL FACE
SHIELD WHEN WORKING WITH BATTERIES.
•ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE. 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 MANUAL.
•TURN KEY SWITCH OFF, PLACE FORWARD/REVERSE ROCKER SWITCH IN THE NEUTRAL POSITION, AND REMOVE
KEY PRIOR TO SERVICING.
•MOVING PARTS! - DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING.
•HOT! - DO NOT ATTEMPT TO SERVICE HOT MOTOR OR RESISTORS. FAILURE TO HEED THIS WARNING COULD
RESULT IN SEVERE BURNS.
•ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CONNECTIONS.
•TO AVOID UNINTENTIONALLY STARTING THE VEHICLE, PLACE THE TOW SWITCH IN THE TOW POSITION AND
DISCONNECT BATTERIES AS SHOWN IN FIGURE 10-1, PAGE 10-2, THEN DISCHARGE THE CONTROLLER AS
FOLLOWS:
-PLACE THE FORWARD/REVERSE ROCKER SWITCH IN THE REVERSE POSITION AND LISTEN FOR THE
REVERSE BUZZER. IF THE REVERSE BUZZER DOES NOT SOUND, THE CAPACITORS ARE DISCHARGED.
-IF THE REVERSE BUZZER SOUNDS, TURN THE KEY SWITCH TO THE ON POSITION AND DEPRESS THE
ACCELERATOR PEDAL UNTIL THE BUZZER CAN NO LONGER BE HEARD.
•IMPROPER MAINTENANCE OR USE OF THE VEHICLE COULD RESULT IN DECREASED VEHICLE PERFORMANCE OR
SEVERE PERSONAL INJURY.
•LIFT ONLY ONE END OF THE VEHICLE AT A TIME. BEFORE LIFTING, LOCK THE BRAKES AND CHOCK THE WHEELS
THAT REMAIN ON THE FLOOR. USE A SUITABLE LIFTING DEVICE (CHAIN HOIST OR HYDRAULIC FLOOR JACK) WITH
1000 LBS. (454 KG.) MINIMUM LIFTING CAPACITY. DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED
POSITION. ALWAYS USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT VEHICLE.
WARNING

PERIODIC MAINTENANCE Daily Pre-Operation Safety Checklist
Page 10-2 1998/1999 PowerDrive Plus Maintenance and Service Supplement
10
DAILY PRE-OPERATION SAFETY CHECKLIST
Inspect and drive the vehicle. Use the Pre-operation Checklist and Performance Inspection in Section 3–General
Information located in the 1998/1999 DS Maintenance and Service Manual as a guide to check the following items.
•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 below:
•Tires: Visually inspect for wear, damage and proper inflation.
•Forward/Reverse switch: Check for proper operation. See Section 3–General Information, Controls, in the
1998/1999 DS Maintenance and Service Manual.
Figure 10-1 Battery Bank for PowerDrive Plus Vehicle
1
2
3
4
6
5
FRONT
OF VEHICLE
REMOVE NEGATIVE
CABLE FIRST
PLACE TOW/RUN SWITCH IN
TOW BEFORE DISCONNECTING
THESE
BATTERY CABLES