section 11–electrical system and testing

section 11–electrical system and testing
11
SECTION 11–ELECTRICAL SYSTEM AND
TESTING
DANGER
• BATTERY - EXPLOSIVE GASES! DO NOT SMOKE. KEEP SPARKS AND FLAMES AWAY.
VENTILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE. ALWAYS WEAR FULL
FACE SHIELD WHEN WORKING ON OR NEAR BATTERIES.
• USE EXTREME CAUTION WHEN USING TOOLS, WIRES, OR METAL OBJECTS NEAR
BATTERIES! A SHORT CIRCUIT AND (OR) SPARK COULD CAUSE AN EXPLOSION.
• BATTERY - POISON! CONTAINS ACID! CAUSES SEVERE BURNS. AVOID CONTACT WITH
SKIN, EYES, OR CLOTHING. ANTIDOTES:
- EXTERNAL: FLUSH WITH WATER. CALL A PHYSICIAN IMMEDIATELY.
- INTERNAL: DRINK LARGE QUANTITIES OF MILK OR WATER. FOLLOW WITH MILK OF
MAGNESIA OR VEGETABLE OIL. CALL A PHYSICIAN IMMEDIATELY.
- EYES: FLUSH WITH WATER FOR FIFTEEN MINUTES. CALL PHYSICIAN IMMEDIATELY.
WARNING
• ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING
EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN
GENERAL ELECTRICAL REPAIR. FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL
WARNING STATEMENTS IN THIS MANUAL.
• WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE.
• TURN KEY SWITCH OFF, PLACE FORWARD/REVERSE HANDLE IN THE NEUTRAL POSITION,
AND REMOVE KEY PRIOR TO SERVICING.
• DO NOT WEAR LOOSE CLOTHING. REMOVE JEWELRY SUCH AS RINGS, WATCHES, CHAINS,
ETC. BEFORE SERVICING VEHICLE.
• USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL
CONNECTIONS.
• TO AVOID UNINTENTIONALLY STARTING THE VEHICLE, DISCONNECT BATTERIES, NEGATIVE
CABLE FIRST, AS SHOWN IN FIGURE 11-1, PAGE 11-2, AND THEN DISCHARGE THE
CONTROLLER AS FOLLOWS:
- TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD/REVERSE HANDLE IN THE
REVERSE POSITION.
- SLOWLY DEPRESS THE ACCELERATOR PEDAL AND KEEP IT DEPRESSED UNTIL THE
REVERSE WARNING BUZZER CAN NO LONGER BE HEARD. WHEN THE BUZZER STOPS
SOUNDING, THE CONTROLLER IS DISCHARGED.
GENERAL INFORMATION
The PowerDrive System 48 vehicle uses a 48-volt electrical system that is powered by six, 8-volt lead-acid
batteries and includes an onboard computer. The PowerDrive System 48 vehicle uses a series wound motor
which increases or decreases the current flow (amperage) through the armature and field coils at the same
rate. Vehicles that incorporate the PowerDrive System 48 include: 1) DS electric golf car, 2) Fairway Villager
electric, 3) Tourall electric, 4) Carryall I, II, and VI electric models, and 5) Trans-Porter, Trans-Sender and
Resort Villager electric models.
1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
Page 11-1
11
ELECTRICAL SYSTEM AND TESTING
BATTERY BANK FOR
DS, CARRYALL I, TOURALL,
FAIRWAY VILLAGER
FRONT
OF VEHICLE
Electrical Circuits
BATTERY BANK FOR CARRYALL II, CARRYALL VI,
RESORT VILLAGER, TRANS-PORTER AND
TRANS-SENDER
2
3
3
FRONT
OF VEHICLE
4
5
5
1
1
REMOVE
NEGATIVE
CABLE FIRST
6
REMOVE
NEGATIVE
CABLE FIRST
2
4
6
DISCONNECT
BATTERY CABLES HERE
Figure 11-1
DISCONNECT
BATTERY CABLES HERE
Battery Configuration
ELECTRICAL CIRCUITS
There are four separate circuits which make up the electrical system of the PowerDrive System 48 vehicle: 1)
the control circuit, 2) the power circuit, 3) the speed control circuit, and 4) the charge circuit. A reverse buzzer
is also included on every vehicle.
CONTROL CIRCUIT
The control circuit consists of:
1. Key switch
2. Forward/Reverse (F&R) anti-arcing limit switch
3. Accelerator limit switch
4. Solenoid Activating Coil
POWER CIRCUIT
The power circuit consists of:
1. Solid state speed controller
2. Solenoid contacts
3. F&R switch
4. Motor
SPEED CONTROL CIRCUIT
For models with a multi-step potentiometer, the speed control circuit consists of the multi-step potentiometer
with discrete resistors. For models equipped with a continuously variable potentiometer, the speed control
circuit includes a solid state potentiometer.
CHARGE CIRCUIT
The charge circuit includes the onboard computer, battery charger, DC charger plug, charger receptacle,
receptacle fuse link (Trans-porter/Trans-sender, and Carryall VI vehicles with onboard chargers will not have
a charger receptacle or receptacle fuse link), and the 8-volt batteries. The onboard fuse link provides additional protection to the vehicle charging circuit. The fuse is rated for use with the Club Car PowerDrive
charger only.
Page 11-2 1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
ELECTRICAL SYSTEM AND TESTING
Electrical Circuits
N
EE
GR
2
1
D
RE E
NG
RA
O
N
OR
W
RO
B
AN
GE
/
I
WH
KEY
SWITCH
TE
REVERSE
BUZZER
FORWARD /
REVERSE
SWITCH
BL
U
E
WARNING
LIGHT
BL
UE
BL
U
W
E
H
YE T/B
G
L
R LLO K
N
/W W
H
T
MULTI-STEP
POTENTIOMETER
E
PL
R
PU
1
CK
E
E
HIT
HIT
/W E
W
/
W
ED
N
G
R
E
N
E
A
N
GR
OR
EE
GR
WH
EE
N/
W
HI
YE TE
LL
O
PU BL W
RP AC
LE K
OW
N
GE
EE
N
LE
RP
PU
RE
D
FUSE
RE
D
+
SOLENOID
D
RE
3
2
YELLOW
1
+
GREEN
BATTERY
BANK
BLUE
2
YELLOW
YELLOW
RED
BROWN
BLACK
GRAY
+
-
RED
D
RE
-
RED/WHITE
PURPLE
BLK
RED
WHITE/ BLACK
EN
GRE
RED
D
RE
K
AC
AY
BL
GR
-
1
-
+
M- B-
+
-
OW
LL
YE
+
5
ITE
UE
BL
K
AC
BL
FUSE AND
RECEPTACLE
-
3
ORANGE
BLUE
WHITE
RE
D
GR
2
GR
BR
AN
LA
/B
E
HIT
SIX-PIN
CONNECTOR
OR
OR
AN
GE
BL
UE
WH
ITE
LIMIT
SWITCHES
+
CONTROLLER
3
4
FUSE
BLACK
BLACK
6
LE
E
RP HIT
PU D/W
E
W
R
O
ITE E
LL
U
WH
YE
BL
B+
THREE-PIN
CONNECTOR
GREEN
GE
AN
OR
A2
S2
BL
AC
K
A1
ONBOARD
COMPUTER
Figure 11-2
S1
MOTOR
Wiring Diagram - DS Electric Vehicle
1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 11-3
11
ELECTRICAL SYSTEM AND TESTING
Electrical Circuits
N
EE
GR
2
D
RE E
NG
A
OR
WN
OR
O
BR
AN
1
GE
/
I
WH
KEY
SWITCH
TE
FORWARD /
REVERSE
SWITCH
REVERSE
BUZZER
BL
UE
MULTI-STEP
POTENTIOMETER
BLUE
WARNING
LIGHT
OR
AN
GE
BL
UE
WH
ITE
LIMIT
SWITCHES
W
H
YE T/B
R LL LK
N O
/W W
H
T
E
PL
R
PU
1
K
AC
E
E
T
HI
HIT
WH
N/W ED/W E
EE
R
NG
GR
A
N
OR
EE
GR
G
/
ITE
SIX PIN
CONNECTOR
3
WH
N/
W
HI
YE TE
LL
O
PU BL W
RP AC
LE K
N
GE
EE
N
UE
BL
K
AC
BL
LE
RP
PU
RE
D
FUSE
RE
D
+
SOLENOID
RED
D
RE
-
GREEN
D
RE
3
2
YELLOW
1
+
BLUE
GRAY
2
YELLOW
YELLOW
RED
BROWN
BLACK
+
-
BATTERY
BANK
RED/WHITE
PURPLE
WHITE/ BLACK
EN
RED
RED
D
RE
+
1
-
+
M-
+
-
OW
LL
YE
K
AC
AY
BL
GR
-
5
GRE
FUSE AND
RECEPTACLE
-
ITE
ORANGE
BLUE
WHITE
RE
D
GR
EE
OW
AN
2
GR
BR
OR
BL
BLK
11
+
CONTROLLER
B-
3
THREE-PIN
CONNECTOR
4
A2
BLACK
BLACK
6
LE
E
RP HIT
PU D/W
E
W
R
O
LL
YE
B+
WHIT
GRE
E
WHIT
EN
ITE
WH
E
U
BL
E
GE
AN
OR
FUSE
A2
BL
AC
K
S2
A1
ONBOARD
COMPUTER
Figure 11-3
Wiring Diagram - Tourall, Carryall I
Page 11-4 1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
S1
MOTOR
ELECTRICAL SYSTEM AND TESTING
Electrical Circuits
KEY
SWITCH
G
2
E
BLU
N
E
RE
1
D
RE
GE /WH
AN
E
OR ANG
OR
ITE
REVERSE
BUZZER
N
OW
BR
HT
N/W
UE
BL
GR
UE
BL
WARNING
LIGHT
N
OW
BR
ONBOARD
COMPUTER
CCW
BROWN
CONTINUOUSLY
VARIABLE
POTENTIOMETER
CW
GR
PU EEN
/W
RP
HI
LL LE
TE
W OW
HT
/B
LK
THREE PIN
PU
RP
LE
S
YE
RE
D/W
HIT
E
EE
N
PLUG
BLACK
3
2
A2
UE
BBLL
ITE
ITE
N
WH
EE
GR
E
NG
UE
BL
ITE
WH
OW
TE
/B
LA
2
E
RED
N
EE
GR
BL
AC
K
D
RE
3
GE
AN
ED
R
CK
/W
OR
W
E
HIT
W
O
HI
RA
T
BL NG E
UE E
N
EE
GR
BLACK
FUSE AND
RECEPTACLE
OW
LL
YE
LL
HI
D
RE
E
D
RE
W
LIMIT
SWITCHES
HIT
E
K
AC
BL
Y
A
GR
YE
1
HIT
K
AC
BL
K
AC
L
B
B+
WH
A
OR
/W
EN
CONTROLLER
ROTATED 180°
B-
M-
FORWARD /
REVERSE
SWITCH
GR
1
RED
WHITE/BLACK
GREEN
K
AC HITE
BL
/W
EN
E
N
GR
OW
BR EEN
R
E
G
HIT
D/W
E
R
FUSE
YELLOW
RED
D
RE
SOLENOID
G
RE
EN
AY
GR
+
FUSE
-
+
+
-
BLK
ORANGE
BROWN
GR
1
-
+
BLACK
RED
+
S2
+
GREEN
2
-
+
A1
S1
5
-
A2
3
-
4
MOTOR
6
BATTERIES
Figure 11-4
Wiring Diagram - Carryall II
1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 11-5
11
ELECTRICAL SYSTEM AND TESTING
Electrical Circuits
N
EE
GR RED
OR
D
RE
AN
/W
GE
HIT
KEY
SWITCH
E
FRONT
REVERSE
BUZZER
WN
O
BR
E
BLU
GE
AN
OR
BATTERY
CONDITION
INDICATOR
2
1
1
WARNING
LIGHT
2
HT
N/W E
GR BLU
UE
BL
N
CONTINUOUSLY
VARIABLE
POTENTIOMETER
OW
BR
ON-BOARD
COMPUTER
BROWN
CW
CCW
GR
PU EEN
/W
RP
HI
LL LE
TE
W
HT OW
/B
LK
S
PU
RP
LE
BL
AC
K
RE
D/W
HIT
E
YE
BLACK
BROWN
EE
N
BLACK
K
AC
BL K
E
AC
BL
HIT
N/W
EE
N
R
G
OW
BR EEN
GR HITE
D/W
RE
3
2
1
M-
FORWARD /
REVERSE
SWITCH
CONTROLLER
ROTATED 180°
B-
A2
K
AC
BL
K
C
A
BL
B+
UE
BL
ITE TE
I
WH
N
WH
EE
GR
GE
AN
FUSE
YELLOW
RED
GREEN
ORANGE
GR
THREE-PIN
PLUG
K
AC
BL
Y
A
GR
D
RE
OW
LL
YE
YELLO
W
OR
RE
D
UE
BL
ITE
WH
W
HI
TE
/B
LA
CK
N
EE
GR
1
3
D/W
RE
GR
GE
AN
OR
BL
AC
K
2
E
HIT
E
HIT
/W
N
EE
W
EN
E
GR
W
REAR
REVERSE
BUZZER
E
HIT
OR
D
RE
FUSE
-
+
HI
BL AN
UE GE
GR
TE
EE
N
SOLENOID
+
-
RG
RE
D
RED
WHITE/BLACK
LIMIT
SWITCHES
R RE
ED D
11
O
+
RED
BLUE
BLACK
CHARGER
BLACK
GREEN
1
-
+
3
+
A2
2
5
S2
-
+
A1
4
S1
MOTOR
6
BATTERIES
Figure 11-5
Wiring Diagram - Carryall VI, Trans-Porter/Trans-Sender
Page 11-6 1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
ELECTRICAL SYSTEM AND TESTING
Electrical Circuits
N
EE
GR RED
2
E
BLU
1
E
NG
A
OR
BATTERY
CONDITION
INDICATOR
OR
A
E
NG
/W
KEY
SWITCH
E
HIT
REVERSE
BUZZER
D
N
RE
OW
BR
1
WARNING
LIGHT
2
HT
N/W E
GR BLU
UE
BL
N
CONTINUOUSLY
VARIABLE
POTENTIOMETER
OW
BR
ONBOARD
COMPUTER
BROWN
CW
GR
PU EEN
/W
RP
HI
LL LE
TE
W
HT OW
/B
LK
S
PU
RP
LE
BL
AC
K
RE
D/W
HIT
E
YE
BLACK
BROWN
EE
N
BLACK
3
2
1
M-
FORWARD /
REVERSE
SWITCH
CONTROLLER
ROTATED 180°
B-
A2
K
AC
BL
CK
A
BL
B+
UE
BL
IT
WH
E
WH
ITE
RED
K
AC
BL K
E
AC
BL
HIT
/W
EN
E
N
GR
OW
BR EEN
GR HITE
D/W
RE
FUSE
YELLOW
K
AC
BL
Y
A
GR
YE
YELLO
W
W
HI
TE
/B
LA
RED
N
CK
LIMIT
SWITCHES
E
RE
G
R
ED
E
HIT
E
HIT
2
3
/W
ED
R
EE
GR
GE
AN
EN
OR
E
GR
BL
AC
K
OW
LL
EN
E
GR
1
N/W
D
RE
RE
D
UE
BL
ITE
WH
WH
ITE
OR
D
RE
W
BL AN
UE GE
FUSE AND
RECEPTACLE
GR
HI
EE
TE
N
SOLENOID
BLACK
Y
RA
G
+
ORANGE
D
RE
GREEN
+
1
-
+
BLACK
-
+
+
FUSE
BLK
GREEN
ORANGE
GR
THREE PIN
PLUG
RED
WHITE/BLACK
CCW
3
+
5
-
+
A2
2
-
S2
4
A1
S1
REAR
REVERSE
BUZZER
RE
D
MOTOR
6
BATTERIES
Figure 11-6
Wiring Diagram - Resort Villager
1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 11-7
11
11
ELECTRICAL SYSTEM AND TESTING
Troubleshooting Guide
TROUBLESHOOTING GUIDE
DIAGNOSTIC REFERENCE CHARTS
Use these charts as a starting point for system troubleshooting. More detailed system testing instructions follow.
Battery Warning Light
In Dash Is Illuminated
DC plug
is connected
DC plug is
disconnected
Light
remains on
Check function
2 on CDM
Light comes on
intermittently
when vehicle
is in use and
when it is
stopped
Glows for
10 seconds
Light
remains on
More than 75
EUs or 75% of
energy removed
from batteries
Open circuit
(no load)
battery voltage
below 48 volts
Batteries did
not receive full
charge, but
may be used
Batteries did
not receive
adequate
charge
No AC present
Restore AC
power.
Light will go
out and charge
will resume
Charge interrupt
(DC cord disconnected
during charge
cycle)
Charge ran
16 hours
Recharge batteries
Check batteries (Section 13)
Check charger (Section 14)
Check OBC (Page 11-20)
OBC is defective
Replace OBC
Figure 11-7 Battery Warning Diagnostic Chart
Page 11-8 1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
ELECTRICAL SYSTEM AND TESTING
Troubleshooting Guide
POWERDRIVE SYSTEM 48 TROUBLESHOOTING GUIDE
SYMPTOM
PROBLEM
POSSIBLE CAUSES
REFER TO
1.
Batteries
1) Battery connections.
Test Procedure 1, Page 11-11
2) Batteries discharged.
Test Procedure 1, Page 11-11
1) Loose wires.
Test Procedure 2, Page 11-11
2) Failed switch.
Test Procedure 2, Page 11-11
1) Loose wires.
Test Procedure 3, Page 11-13
2) Failed switch.
Test Procedure 3, Page 11-13
3) Cam is not activating switch.
Section 12–Electrical Components, F&R Anti-arcing Limit
Switch
Vehicle will not operate no solenoid click.
Key Switch
F&R Anti-arcing Limit
Switch
Accelerator
1) Accelerator rod disconnected. Section 5–Accelerator and
(Multi-step Pot. vehicles only) Brake Pedal
Accelerator Pedal Limit
Switch
1) Loose wire.
Test Procedure 4, Page 11-13
2) Disconnected or
improperly connected wires.
Figures 11-2 through 11-6,
Pages 11-3 through 11-7
3) Failed switch.
Test Procedure 4, Page 11-13
1) Loose wires.
Test Procedure 5, Page 11-14
2) Failed coil.
Test Procedure 5, Page 11-14
3) Failed solenoid diode.
Test Procedure 5, Page 11-14
Controller Electrical Leakage
1) Dirt or acid residue on the
controller.
Test Procedure 10, Page 1118
Onboard Computer
1) Battery connections.
Figure 11-1, Page 11-2
2) Onboard computer solenoid
lockout failure.
Test Procedure 11, Page 1120
1) Battery connections.
Test Procedure 1, Page 11-11
2) Batteries discharged.
Test Procedure 1, Page 11-11
Solenoid
1) Loose wires.
Figures 11-2 through 11-6,
Pages 11-3 through 11-7
2) Failed contacts.
Test Procedure 7, Page 11-15
Forward and Reverse
Switch
1) Loose wires.
Test Procedure 6, Page 11-14
2) Failed contacts.
Test Procedure 6, Page 11-14
Potentiometer
1) Loose wires.
Figures 11-2 through 11-6,
Pages 11-3 through 11-7
2) Improperly wired.
Figures 11-2 through 11-6,
Pages 11-3 through 11-7
3) Short or open circuit.
Test Procedures 8 or 9, pages
11-16 and 11-17
4) Improperly adjusted.
Section 5–Accelerator &
Brake Pedal
1) Loose wires.
Test Procedure 10, Page 1118
2) Defective Controller.
Test Procedure 10, Page 1118
1) Loose wires.
Section 15–Motor
2) Open/shorted
windings.
Section 15–Motor
Solenoid
2. Vehicle will not operate solenoid clicks.
Batteries
Controller
Motor
1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 11-9
11
11
ELECTRICAL SYSTEM AND TESTING
Troubleshooting Guide
POWERDRIVE SYSTEM 48 TROUBLESHOOTING GUIDE
SYMPTOM
PROBLEM
POSSIBLE CAUSES
REFER TO
3. Vehicle runs slowly.
Wiring
1) Improperly wired.
Figures 11-2 through 11-6,
Pages 11-3 through 11-7
Batteries
1) Loose terminals or corrosion.
Test Procedure 1, and
Section 13–Batteries
2) Improperly wired.
Test Procedure 1 and
Section 13–Batteries
3) Batteries failed.
Test Procedure 1 and
Section 13–Batteries
4) Batteries not fully charged.
Test Procedure 1 and
Batteries, Section–13
1) Loose wires.
Section 15–Motor
2) Defective motor.
Section 15–Motor
1) Improperly adjusted.
Test Procedures 8 and 9,
page 11-16 and 11-17
2) Defective potentiometer.
Test Procedures 8 and 9,
page 11-16 and 11-17
Half-speed Reverse Limit
Switch
1) Failed in the closed position.
Test Procedure 12, Page 11-21
2) Improperly wired.
Figures 11-2 through 11-6,
Pages 11-3 through 11-7
Controller
1) Vehicle overload.
Let controller cool, remove
part of load.
2) Defective controller.
Test Procedure 10, Page 11-18
Brakes
1) Dragging brakes.
Section 6–Brakes
Tires
1) Under-inflated or flat tires.
Section 8–Wheels and Tires
Forward/Reverse Half-speed
Reverse Limit Switch
1) Loose or disconnected wires.
Section 12–Electrical Components
2) Failed switch.
Section 12–Electrical Components
Motor
Potentiometer
4.
5.
6.
Vehicle runs full speed in
reverse.
Vehicle will run in forward but
not in reverse, or will run in
reverse but not forward.
Vehicle not being fully
charged.
Half speed (5100 ohm) Resis- 1) Resistor is disconnected or
tor
has failed.
Test Procedure 13, Page 1121
Forward/Reverse Anti-arcing
Limit Switch
1) Loose or broken wires.
Test Procedure 3 and
Section 12–Electrical Components
2) Improper actuation of switch.
Test Procedure 3 and
Section 12–Electrical Components
3) Improperly wired.
Test Procedure 3 and
Section 12–Electrical Components
Forward/Reverse
Switch
1) Poor continuity of switch
contacts.
Test Procedure 6, Page 11-14
Charger Connections
1) Loose wires at receptacle or
batteries.
Section 14–PowerDrive
Charger
Charger
1) Incorrect incoming AC voltage.
Section 14–PowerDrive
Charger
2) Charger output is low.
Section 14–PowerDrive
Charger
3) Charger cord and plugs.
Section 14–PowerDrive
Charger
Page 11-10 1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
ELECTRICAL SYSTEM AND TESTING
Circuit Testing
POWERDRIVE SYSTEM 48 TROUBLESHOOTING GUIDE
SYMPTOM
PROBLEM
POSSIBLE CAUSES
REFER TO
6.
Charger, Continued:
4) Charger relay.
Section 14–PowerDrive
Charger
5) Charger fuse is blown.
Section 14–PowerDrive
Charger
Charger/Onboard Computer
1) Improper charging.
Section 14–PowerDrive
Charger
Vehicle not being fully
charged (continued).
7.
Vehicle runs without pressing
the accelerator when the key
is on and the Forward/
Reverse Switch is in forward
or reverse.
Accelerator
1) Improper pedal adjustment.
Section 5–Accelerator and
Brake Pedal Group
8.
Solenoid clicks when the key
is turned on.
Accelerator Limit Switch
1) Defective switch.
Test Procedure 4, Page 11-13
2) Improper pedal adjustment.
Section 5–Accelerator and
Brake Pedal Group
CIRCUIT TESTING
Read DANGER and WARNING on page 11-1.
Using the following procedures, the entire PowerDrive electrical system can be tested without major disassembly of the vehicle.
CAUTION
• IF WIRES ARE REMOVED OR REPLACED MAKE SURE WIRING AND/OR WIRING HARNESS IS
PROPERLY ROUTED AND SECURED TO VEHICLE FRAME. FAILURE TO PROPERLY ROUTE
AND SECURE WIRING COULD RESULT IN VEHICLE MALFUNCTION, PROPERTY DAMAGE OR
PERSONAL INJURY.
NOTE
• VEHICLES PRODUCED LATE IN THE 1999 MODEL YEAR MAY NOT HAVE A RUBBER BOOT
ATTACHED TO THE 6 GAUGE RED WIRE AT THE SOLENOID.
CONTROL CIRCUIT
Test Procedure 1 - Batteries / Voltage Check
1. With batteries connected and using a multimeter set to 200 volts DC, place red (+) probe on the positive post of battery No. 1 and the black (-) probe on the negative terminal of battery No. 6. The multimeter should indicate at least 48 volts with the batteries fully charged. If not, check for loose battery
connections or a battery installed in reverse polarity. Refer to Section 13–Batteries, for further details
on battery testing (Figures 11-8 or 11-9, Page 11-12).
Test Procedure 2 - Key Switch
Vehicles with Multi-step (Wiper Switch) Potentiometer:
1. With batteries disconnected, place red (+) probe of multimeter set to 200 Ω (ohms) on large terminal of
solenoid (with red wire attached) and place black (-) probe at blue wire position in the six-pin connector
on the key switch side (Figure 11-10, Page 11-12).
1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 11-11
11
11
ELECTRICAL SYSTEM AND TESTING
Circuit Testing
Test Procedure 2–Key Switch, Continued:
-
200 DCV
SETTING
+
-
WAVETEK
BATTERY BANK FOR DS,
CARRYALL I, TOURALL,
AND FAIRWAY VILLAGER
5XL
V
OFF
1000
V
500
200
200
20
200 DCV
SETTING
+
WAVETEK
V
200
200
2m
200
m
200
m
2000
k
500
2
20
m
BATTERY BANK FOR CARRYALL II,
CARRYALL VI, RESORT VILLAGER,
TRANS-PORTER, TRANS-SENDER,
AND ALL XL VEHICLES
V
OFF
20
2m
2
200
m
5XL
1000
200
200
20
m
200
m
2000
k
200k
200k
20k
Ω
200
A
2k
20k
Ω
200
A
2k
FRONT
OF VEHICLE
Ω
V
!
!
COM
MAX
1000 --750V
200nA
Ω
V
!
!
COM
MAX
1000 --750V
2
FUSED
200nA
FRONT
OF VEHICLE
FUSED
3
5
1
6
1
3
5
2
4
4
6
Figure 11-8 Battery Test - Short Frame Vehicle
READING SHOULD BE
LESS THAN 100 OHMS
Figure 11-9 Battery Test - Long Frame Vehicle
READING SHOULD BE
LESS THAN 100 OHMS.
TO THE POSITIVE POST
ON BATTERY NUMBER 1
-
FORWARD
AND REVERSE
SWITCH
+
-
WAVETEK
V
5XL
1000
OFF
WAVETEK
V
500
200
+
V
5XL
1000
OFF
V
500
WHITE/BLACK
WIRE
200
200
20
200
200
20
200
2m
2
2m
2
200
m
20
m
200
m
200
m
2000
k
20
m
200
m
2000
k
200k
20k
Ω
200k
200
A
2k
20k
Ω
200
A
2k
GREEN/WHITE
WIRE
RED
WIRE
V
Ω
!
!
COM
200nA
V
MAX
1000 --750V
Ω
!
MAX
1000 --750V
FUSED
6-PIN CONNECTOR
!
COM
200nA
FUSED
SOLENOID
SOLENOID
200 Ω SETTING
200 Ω SETTING
WITH KEY SWITCH ON
WITH KEY SWITCH ON
Figure 11-10 Test Key Switch
(Multi-step Potentiometer Vehicles)
Figure 11-11 Test Key Switch (All Electric Vehicles)
2. With the key switch OFF, the reading should be no continuity. If continuity is shown, check the key
switch, wires and terminals, and then replace defective parts.
3. Insert the key and turn the switch ON. The reading should be continuity (less than 100 ohms).
4. If the reading is incorrect, check the key switch, wires and terminals, and then replace defective parts.
5. Reconnect six-pin connector.
6. Place red (+) probe of multimeter on large terminal of solenoid (with red wire attached) and place black
(-) probe at green/white wire from the Forward/Reverse limit switch No. 1 (Figure 11-11, Page 11-12).
7. Depress and hold the accelerator pedal to activate the accelerator pedal limit switch.
8. With the key switch OFF the reading should be no continuity.
9. Insert key and turn switch ON while continuing to depress accelerator pedal. Reading should be continuity
(less than 100 ohms).
10. If reading is incorrect, check accelerator limit switch, wires and terminals, and replace defective parts.
Page 11-12 1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
ELECTRICAL SYSTEM AND TESTING
Circuit Testing
Vehicles with Continuously Variable Potentiometer:
1. Place red (+) probe of multimeter on large terminal of solenoid (with red wire attached) and place black
(-) probe at green/white wire from the Forward/Reverse limit switch No. 1 (Figure 11-11, Page 11-12).
2. Depress and hold the accelerator pedal to activate the accelerator pedal limit switch.
3. With the key switch OFF the reading should be no continuity (less than 100 ohms).
4. Insert key and turn switch ON while continuing to depress accelerator pedal. Reading should be continuity.
5. If the reading is incorrect, check the key switch, accelerator limit switch, wires and terminals, and
replace defective parts.
Test Procedure 3 - Forward/Reverse Anti-Arcing Limit Switch
NOTE
• THERE ARE THREE LIMIT SWITCHES ON THE FORWARD/REVERSE SWITCH. THE FORWARD/
REVERSE ANTI-ARCING LIMIT SWITCH IS THE ONE CLOSEST TO THE VEHICLE BODY.
FORWARD AND REVERSE
SWITCH
-
WHITE/BLACK WIRE
+
WAVETEK
V
5XL
1000
OFF
V
500
200
200
20
200
2m
2
200
m
GREEN/WHITE
WIRE
20
m
200
m
2000
k
200k
20k
Ω
V
Ω
!
MAX
1000 --750V
200
A
2k
!
COM
200nA
FUSED
200 Ω SETTING
SOLENOID
WHITE/BLACK WIRE
Figure 11-12 F&R Anti-Arcing Limit Switch
1. With batteries disconnected, place the red (+) probe of the multimeter (set for 200 ohms) on the small activating coil post of the solenoid that has the white/black and red wires connected. Place the black (-) probe
on the No. 1 anti-arcing limit switch at the normally open (NO) terminal (Figure 11-12, Page 11-13).
2. Reading should show continuity when Forward/Reverse handle is placed in either FORWARD or REVERSE
and no continuity when in NEUTRAL and when in FORWARD or REVERSE (until the rotor contacts are in
contact with contact bars). If not, check wires and terminals. If readings are still incorrect, replace switch.
Test Procedure 4 - Accelerator Pedal Limit Switch
Vehicles with Multi-step (Wiper Switch) Potentiometer:
1. With batteries disconnected, place black (-) probe of multimeter, set for 200 ohms, on green/white wire
terminal from six-pin connector on the wiper switch side and red (+) probe at the blue wire position at
the six-pin connector on wiper switch side (Figure 11-13, Page 11-14).
2. With the accelerator pedal fully up (not depressed), the reading should be no continuity.
3. With the key switch OFF, depress the accelerator pedal. The reading should be continuity.
4. If readings for steps 2 and 3 are not correct, check wire connection at the normally closed (NC) and common
(COM) terminals of accelerator pedal limit switch (located inside wiper switch). Check accelerator pedal adjustment. See Section 5–Accelerator and Brake Pedal.
5. If wires are connected correctly and accelerator pedal is properly adjusted, but readings are still not
correct, replace limit switch.
1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 11-13
11
11
ELECTRICAL SYSTEM AND TESTING
Circuit Testing
Vehicles with Continuously Variable Potentiometer:
1. With batteries disconnected, controller discharged and the key switch in the ON position, connect the
red lead of a multimeter (set for 200 ohms) to the large post of the solenoid (with 6 gauge red wire
attached) and connect the black lead of the multimeter to the green/white wire from limit switch No. 1
on the Forward/Reverse switch (Figure 11-14, Page 11-14).
1.1. With the accelerator pedal fully upright (not depressed), the reading should be no continuity.
1.2. With the accelerator pedal depressed, the reading should be continuity.
2. If these readings are not obtained, check to be sure that the wires are connected properly to the normally open (NO) and common (COM) terminals of the accelerator pedal limit switch located on the continuously variable potentiometer. Check accelerator pedal adjustment. See Section 5–Accelerator
and Brake Pedal for information regarding accelerator and brake pedal adjustment.
3. If wires are connected correctly and accelerator pedal is properly adjusted, but readings are incorrect,
replace accelerator pedal limit switch.
-
-
+
WAVETEK
V
WAVETEK
5XL
1000
OFF
V
V
5XL
1000
500
200
OFF
V
500
200
200
200
200
200
m
200
m
20
m
20
m
200k
200k
20k
Ω
200
m
2000
k
200
m
2000
k
2m
2
2m
2
200
20k
Ω
A
2k
200
A
2k
V
Ω
MAX
1000 --750V
!
COM
200nA
FUSED
200 Ω SETTING
Figure 11-13 Test Limit Switch (Multi-step)
GREEN/WHITE
WIRE
RED
WIRE
SIX-PIN CONNECTOR
!
WHITE/BLACK
WIRE
200
20
20
FORWARD
AND REVERSE
SWITCH
+
V
Ω
!
MAX
1000 --750V
!
COM
200nA
FUSED
SOLENOID
200 Ω SETTING
WITH PEDAL UP
Figure 11-14 Test Limit Switch (Cont. Variable)
Test Procedure 5 - Solenoid Activating Coil
1. With batteries disconnected, remove the diode terminal end from the small post on the solenoid (with 18
gauge yellow wire attached).
2. Make sure that the diode direction is correct (Figures 11-2 through 11-6, Pages 11-3 through 11-7).
The red terminal end of the diode attaches to the small post on the solenoid (with 18 gauge red wire
and 18 gauge white/black striped wire attached).
3. Using a multimeter set for diode, check for continuity between both diode terminals. Reverse the tester
leads and again check for continuity. A diode is designed to conduct current in one direction only. If a
diode shows continuity in both directions or does not show continuity in either direction, replace the
diode assembly (Figure 11-15, Page 11-15).
4. With diode assembly and yellow wire removed from the small activating coil post of the solenoid, place
red (+) probe of the multimeter on the post. Place the black (-) probe on the other small activating coil
post on the solenoid. A reading of 190 to 250 ohms should be obtained. If not, replace the solenoid. If
the ohm reading is correct, reconnect the diode assembly and yellow wire (Figure 11-16, Page 11-15).
POWER CIRCUIT
Test Procedure 6 - Forward/Reverse (F&R) Switch
1. Disconnect batteries and use a multimeter (set to 200 Ω) to test the F&R switch in both directions. With Forward/
Reverse handle in FORWARD, place red (+) probe of multimeter on M- terminal of speed controller and place
black (-) probe on S1 motor terminal. Meter should indicate continuity (Figure 11-17, Page 11-15).
2. With Forward/Reverse handle in FORWARD, place red (+) probe on A2 motor terminal, and place the
black (-) probe on the S2 motor terminal. Meter should indicate continuity (Figure 11-18, Page 11-15).
Page 11-14 1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
ELECTRICAL SYSTEM AND TESTING
Circuit Testing
3. With Forward/Reverse handle in REVERSE, place red (+) probe on speed controller M- terminal and place
black (-) probe on S2 motor terminal. Meter should indicate continuity (Figure 11-19, Page 11-16).
4. With Forward/Reverse handle in REVERSE, place red (+) probe on the A2 motor terminal and the
black (-) probe on the S1 motor terminal. Meter should indicate continuity. If continuity cannot be
obtained, and all wires and connections are correct, replace F&R switch (Figure 11-20, Page 11-16).
-
RED RING
TERMINAL
+
-
WAVETEK
V
5XL
1000
WAVETEK
V
OFF
+
500
V
200
5XL
1000
OFF
V
500
200
200
20
200
200
20
2m
2
200
m
200
m
200
m
2000
k
20
m
200
m
2000
k
200k
20k
2m
2
20
m
Ω
200k
200
A
2k
20k
Ω
Ω
V
200
!
!
COM
200nA
Ω
V
MAX
1000 --750V
!
200
!
COM
MAX
1000 --750V
FUSED
A
2k
200nA
FUSED
DIODE
DIODE SETTING
SOLENOID
2K Ω SETTING
Figure 11-15 Test Diode
Figure 11-16 Test Activating Coil
MOTOR
CONTROLLER
S22
S11 A
A
-
+
-
WAVETEK
V
5XL
1000
OFF
200
+
M-
V
500
WAVETEK
200
V
20
200
200
2m
200
m
20
m
200
m
2000
k
A
2k
200
2
200k
20k
V
500
20
200
m
Ω
OFF
200
2m
20
m
2000
k
5XL
1000
200
2
200
m
200k
20k
Ω
V
Ω
!
!
COM
A
200nA
FUSED
200 Ω SETTING
MOTOR
S22
S11 A
A
MAX
1000 --750V
200
2k
Figure 11-17 Test F&R (Forward Position)
V
Ω
!
!
COM
MAX
1000 --750V
200nA
FUSED
200 Ω SETTING
Figure 11-18 Test F&R Continuity (Reverse Position)
Test Procedure 7 - Solenoid Contacts (Power Off)
1. With batteries disconnected, remove the yellow wire and red wire from the large posts of the solenoid.
Remove resistor assembly. Place the red (+) probe of the multimeter on one of the large posts of the
solenoid and the black (-) probe of the meter on the other large post on the solenoid. Multimeter should
indicate no continuity. If multimeter indicates continuity, replace solenoid (Figure 11-21, Page 11-16).
2. Using a multimeter, check for resistance between both resistor terminals. If reading is not approximately 250 ohms, replace the resistor (Figure 11-22, Page 11-16).
1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 11-15
11
11
ELECTRICAL SYSTEM AND TESTING
Circuit Testing
CONTROLLER
-
+
MOTOR
WAVETEK
V
5XL
1000
V
OFF
500
200
200
20
200
2m
2
200
m
20
m
200
m
2000
k
M-
200k
20k
Ω
200
A
2k
!
!
MAX
1000 --750V
S22
S1 1 A
A
-
Ω
V
+
200nA
FUSED
WAVETEK
5XL
V
1000
OFF
V
500
200
200
20
2m
2
S22
S1 1 A
A
200 Ω SETTING
200
200
m
20
m
200
m
2000
k
200k
20k
Ω
MOTOR
V
Ω
!
200
!
COM
MAX
1000 --750V
Figure 11-19 Test F&R (Reverse Position)
A
2k
200nA
FUSED
Figure 11-20 Test F&R Continuity (Reverse Position)
SPEED CONTROL CIRCUIT
Test Procedure 8 - Multi-step Potentiometer
1. Disconnect the battery cables (negative cable first) and then disconnect the six-pin connector at multistep potentiometer. Remove switch cover by pressing down on locking tabs.
2. With multimeter set for 20K ohms, connect black (-) lead of multimeter to purple wire terminal end
(located in six-pin connector on potentiometer). Connect red (+) probe to yellow wire terminal end (Figure 11-23, Page 11-17).
-
+
-
WAVETEK
V
5XL
1000
OFF
+
WAVETEK
V
V
2m
200
2m
2
20
m
V
200k
20k
Ω
!
MAX
1000 --750V
200
m
2000
k
200k
Ω
200
200
m
20
m
200
m
2000
k
V
500
20
200
2
OFF
200
200
200
m
5XL
1000
500
200
20
200
!
COM
20k
Ω
A
2k
200nA
V
Ω
!
MAX
1000 --750V
FUSED
200 Ω SETTING
200
A
2k
!
COM
200nA
FUSED
RESISTOR
2K Ω SETTING
SOLENOID
Figure 11-21 Test Solenoid Contacts
Figure 11-22 Test Resistor
3. Depress the accelerator pedal until wiper switch movable contact is on third stationary contact. Multimeter should register approximately 565 ohms.
4. Measure resistance while depressing the accelerator pedal. The measured resistance should increase
incrementally in six steps:
1st Step:
910 ohms (approx.)
2nd Step:
1660 ohms (approx.)
3rd Step:
2570 ohms (approx.)
Page 11-16 1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
ELECTRICAL SYSTEM AND TESTING
4th Step:
5th Step:
3570 ohms (approx.)
4570 ohms (approx.)
6th Step:
5570 ohms (approx.)
Circuit Testing
NOTE
• IF AN INCREASE IN RESISTANCE FROM 0 TO (APPROXIMATELY) 5000 OHMS IS OBTAINED
WHEN THE ACCELERATOR PEDAL IS DEPRESSED WITHOUT EXCEEDING (APPROXIMATELY)
7000 OHMS, THEN THE SPEED SWITCH RESISTOR ASSEMBLY IS IN GOOD CONDITION.
5. If the resistance steps were not correct and the accelerator pedal is properly adjusted, then replace
multi-step potentiometer.
6. Replace wiper switch cover and reconnect six-pin connector assembly.
Test Procedure 9 - Continuously Variable Potentiometer
1. Disconnect the battery cables (negative cable first) and then disconnect the three-pin connector from
the main wire harness. The connector emerges from under the front body floorboard (Figure 11-25,
Page 11-18). Turn key switch ON and place Forward/Reverse handle in NEUTRAL.
2. Connect Calibration Test Module (CTM) (Club Car Part number 101887101) to the three-pin connector
using plug adapter (Club Car Part Number 101984501) (Figure 11-24, Page 11-17).
3. Turn CTM ON. Set mode switch to POT. With accelerator pedal fully upright, reading should be approximately 3.62 volts.
4. Press accelerator pedal to the floor. Voltage reading should be 0 volts. If readings are not correct, see
Potentiometer Adjustment Procedure in Section 5–Accelerator and Brake Pedal, in the appropriate
Maintenance and Service Base Manual.
ALLIGATOR CLIP
(18 GAUGE WHITE WIRE)
SEE TEST PROCEDURE 8,
STEP 4 FOR OHM READINGS
-
+
WAVETEK
V
5XL
1000
OFF
THREE-PIN CONNECTOR
MALE TERMINAL
(18 GAUGE GREEN
WIRE)
V
500
200
200
20
200
THREE-PIN CONNECTOR
ADAPTER
2m
2
200
m
20
m
200
m
2000
k
200k
20k
Ω
200
A
2k
LCD DISPLAY
WINDOW
SIX-PIN CONNECTOR
V
Ω
!
MAX
1000 --750V
!
COM
200nA
LED
DISPLAY
FUSED
UPPER CALIBRATION SCREW
CALIBRATION & TEST MODULE
INSTRUCTIONS
SPEED CONTROL
SET POWER SWITCH TEST
TO "ON".
20K Ω SETTING
PEDAL CIRCUIT
POT CALIBRATION: SET MODE SWITCH TO "POT".
CHECK INTERNAL 4.30±.03 VOLT SIGNAL BY PRESSING "TEST" BUTTON.
CONNECT TEST SOCKET TO POT PLUG, CONNECT GREEN LEAD TO GREEN/
WHITE POT LIMIT SWITCH LEAD, CONNECT BLUE LEAD TO BATTERY
POSITIVE. ILLUMINATION OF THE L.E.D. INDICATES A CLOSED
PEDAL LIMIT SWITCH, READ THE POTENTIOMETER SET VOLTAGE FROM THE
L.C.D. DISPLAY. SEE SERVICE MANUAL FOR ADJUSTMENT PROCEDURE.
SPEED SENSOR TEST: SET MODE SWITCH TO "SSAM", CONNECT TEST
SOCKET TO MOTOR SPEED SENSOR PLUG, ROTATE MOTOR. L.E.D. SHOULD
PULSE ON AND OFF INDICATING SPEED SENSOR IS FUNCTIONAL.
SEE OPERATING INSTRUCTIONS FOR MORE DETAIL
POWER
ON
OFF
Figure 11-23 Test Multi-step Potentiometer
R
Club Car
MODE
SSAM
POT
LOWER CALIBRATION SCREW
(CALIBRATION SCREWS
ARE UNDER DECAL AT
TARGET POINTS)
TEST
BUTTON
Figure 11-24 Calibration Test Module
1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 11-17
11
11
ELECTRICAL SYSTEM AND TESTING
Circuit Testing
THREE-PIN CONNECTOR
TO POTENTIOMETER
WIRE HARNESS TO
THE F&R SWITCH
Figure 11-25 Three-Pin Connector
Test Procedure 10 - Solid State Speed Controller
Read DANGER and WARNING on page 11-1.
DANGER
• TURN KEY TO OFF, PLACE FORWARD/REVERSE HANDLE IN NEUTRAL AND DISCONNECT
BATTERY CABLES AS SHOWN IN FIGURE 11-1, PAGE 11-2. FAILURE TO DO SO MAY CAUSE
THE VEHICLE TO RUN OVER YOU, RESULTING IN SEVERE INJURY OR DEATH.
CONTROLLER
CONTROLLER
-
+
-
WAVETEK
V
5XL
1000
OFF
V
500
200
200
+
WAVETEK
B-
V
5XL
1000
OFF
V
500
200
20
20
2m
2
20
m
200
m
200
m
2000
k
20k
!
MAX
1000 --750V
20
m
200
m
2000
k
200k
Ω
Ω
200
2m
2
200
m
V
B+
200
200
A
20k
Ω
!
COM
M-
200k
200
2k
200nA
V
Ω
!
MAX
1000 --750V
FUSED
200 DCV SETTING
200
A
2k
!
COM
200nA
FUSED
RED WIRE
Figure 11-26 Test Input Voltage
200 DCV SETTING
Figure 11-27 Test Output Voltage
1. Because the solid state speed controller is a sealed solid state unit, it requires almost no maintenance.
It is recommended, however, the following two operations be done occasionally.
1.1. Make sure electrical connections to controller are tight. When checking controller bus bar connections for
tightness, be sure to use double-wrench technique to avoid stressing bus bars and cracking seals.
1.2. Remove any corrosion or accumulation of dirt, acid, fertilizer etc., from the terminal area. It is
especially important that the controller terminal face be free of dirt and debris to help prevent
electrical leakage that could cause faulty operation.
2. Check for solenoid input.
NOTE
• BEFORE ATTEMPTING THE FOLLOWING TESTS, THE REAR OF THE VEHICLE MUST BE
RAISED AND SECURED ON JACKSTANDS WITH THE DRIVE WHEELS OFF THE GROUND.
Page 11-18 1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
ELECTRICAL SYSTEM AND TESTING
Circuit Testing
WARNING
• LIFT ONLY ONE END OF THE VEHICLE AT A TIME. BEFORE LIFTING, UNLOAD THE CARGO
BED, 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 THE VEHICLE.
2.1. Disconnect the batteries, negative cable first and discharge the controller as instructed in the
WARNING on page 11-1 (Figure 11-1, Page 11-2). Remove the 6 gauge white wire from the A2
motor terminal and secure wire so it will not make contact with any live components or connections. Reconnect batteries, positive cable first (Figure 11-1, Page 11-2).
2.2. Place Forward/Reverse handle in either FORWARD or REVERSE, turn key to ON, and depress accelerator pedal until limit switches activate. This should cause solenoid to operate with an audible click.
2.3. Connect multimeter (set to 200 volts DC) across solenoid small activating posts. Multimeter should read
full battery voltage when accelerator is depressed to the floor.
3. Check for controller input voltage.
3.1. Place Forward/Reverse handle in either FORWARD or REVERSE, turn key ON, and depress accelerator pedal until limit switches activate. This should cause solenoid to operate with an audible click.
3.2. Remove the 18 gauge red wire from controller input terminal 1.
3.3. Place multimeter (set for 200 volts DC) black probe (-) on B- terminal of controller (with 6 gauge black
wire attached) and red probe (+) into terminal end of red wire removed from controller terminal 1. Multimeter should indicate full battery voltage with accelerator pedal pressed to floor (Figure 11-26,
Page 11-18).
3.4. If the controller input terminal is not getting full battery voltage, then check wire and connections
between the solenoid small post and controller 1 terminal. Replace defective parts.
3.5. Disconnect battery wires, negative cable first (Figure 11-1, Page 11-2) and discharge the controller as instructed in the WARNING on page 11-1. Reconnect the 6 gauge white wire to the A2
motor terminal. Reconnect batteries.
4. Check for controller output.
4.1. Disconnect battery wires. Remove 6 gauge white wire from A2 motor terminal and secure wire so
that it cannot make contact with any live components or connections. Reconnect battery wires.
4.2. Connect the multimeter (set for 200 volts DC) red probe (+) to the controller B+ terminal and the black
probe (-) to the controller M- terminal. The multimeter should display approximately 48 volts, which is
controller capacitor voltage (Figure 11-27, Page 11-18).
4.3. Turn key switch ON, place Forward/Reverse handle in FORWARD and watch multimeter as you
depress the accelerator pedal. With the accelerator pedal fully depressed, the multimeter should
indicate full battery voltage. If the multimeter reading does not rise to full battery voltage (with a
properly functioning potentiometer and correct pedal adjustment), then the controller is defective.
4.4. Discharge the controller as instructed in WARNING on page 11-1. Attach the 6 gauge white wire
to the A2 motor terminal. Reconnect batteries, positive cable first (Figure 11-1, Page 11-2).
For 48-Volt vehicles excluding the DS:
5. Check for diode.
5.1. Disconnect battery wires as shown (Figure 11-1, Page 11-2) and discharge controller as
instructed in WARNING on page 11-1.
1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 11-19
11
11
ELECTRICAL SYSTEM AND TESTING
Circuit Testing
Test Procedure 10–Solid State Speed Controller, Continued:
5.2. Using two wrenches to keep the posts from turning, remove wires from controller B+ terminal.
5.3. Use a multimeter (set to Diode) to test the resistance between the controller A2 and B+ terminals.
This test is for the presence of a functioning diode inside the controller. If the diode is shorted
either open or closed, the controller is defective. With the black (-) probe on the B+ terminal and
the red (+) probe on the A2 terminal, reading should indicate continuity. Reverse leads and reading should indicate no continuity.
5.4. Reconnect wires to controller B+ terminal. Reconnect batteries, positive cable first (Figure 11-1,
Page 11-2).
Test Procedure 11 - Onboard Computer Lockout Circuit
For vehicles with charger receptacles, follow step 1.
1. Inspect the charger receptacle for water in the contacts. If water is found, proceed as follows:
NOTE
• IF BATTERY PACK IS WET, MAKE SURE 18 GAUGE GRAY WIRE FROM OBC IS NOT
TOUCHING BATTERIES. WIRE TIE THE 18 GAUGE GRAY LEAD AND 18 GAUGE GRAY WIRE
TO WIRE HARNESS IF NECESSARY.
1.1. Disconnect the batteries, negative cable first, as shown (Figure 11-1, Page 11-2).
1.2. Discharge the controller. See instructions in the WARNING on page 11-1.
1.3. Remove the receptacle from the vehicle. See Section 12–Electrical Components.
1.4. Dry receptacle by wiping with a clean dry cloth and by blowing into contacts with compressed air.
1.5. Reinstall the charger receptacle.
2. With batteries disconnected, inspect the sense lead fuse in the gray wire from OBC. Using a multimeter (set
to 200 Ω), check fuse for continuity. If continuity is present, fuse is good. If no continuity is present, fuse is
blown. Replace the fuse if blown.
3. It is possible the OBC can become “locked-up”, causing the OBC solenoid lockout circuit to malfunction. If this condition is suspected, restart the computer as follows:
3.1. Disconnect the batteries, negative cable first, as shown (Figure 11-1, Page 11-2) and discharge
the controller. See instructions in the WARNING on page 11-1.
3.2. Reconnect the batteries, positive cable first and tighten terminals to 110 in.lb (12.4 N-m). Drive the
vehicle. If the problem has been corrected, the vehicle will function normally.
NOTE
• A CHANGE IN THE DESIGN OF THE OBC RESULTED IN THE INCORPORATION OF A FIELD
EMITTING TRANSISTOR (FET) PROTECTION SYSTEM WITHIN THE SOLENOID LOCKOUT CIRCUIT.
THIS PROTECTS THE FET FROM BEING BLOWN AND ALLOWS IT TO BE RESET. THE NEW OBC’S
ARE MARKED WITH THE NUMBER V1.35P ON THE LABEL (FIGURE 11-28, PAGE 11-21). VEHICLES
WITH SERIAL NUMBERS 9841-703262 AND GREATER ARE EQUIPPED WITH THIS NEW FET
PROTECTION SYSTEM.
Vehicles with serial numbers 9841-703262 and greater proceed to step 4. Vehicles with serial numbers lower than 9841-703262, proceed to step 5.
4. Disconnect battery cables, negative cable first, and inspect wire terminals. Make sure wire terminals are not
touching corresponding solenoid terminal posts. Reconnect battery cables and attempt to drive the vehicle.
5. If vehicle cannot be driven, disconnect battery cables and solenoid. Remove and replace solenoid
diode, reconnect solenoid, (making sure wires are correctly positioned) reconnect battery cables and
attempt to drive the vehicle. If vehicle still does not respond, proceed with step 6.
Page 11-20 1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
ELECTRICAL SYSTEM AND TESTING
Circuit Testing
6. Bypass the OBC solenoid lockout circuit to isolate the problem. Use the following procedure:
6.1. Make sure the batteries are disconnected as shown (Figure 11-1, Page 11-2) and the controller
has been discharged. See instructions in the WARNING on page 11-1.
6.2. Connect one end of a jumper wire to the small (coil) post of the solenoid (with 18 gauge yellow
wire attached). Connect the other end of the jumper wire to the negative post of battery No. 6.
6.3. Reconnect the batteries, positive cable first, and tighten terminals to 110 in.lb (12.4 N-m).
6.4. If vehicle can be driven with jumper wire attached, then OBC has failed and must be replaced. If
vehicle cannot be driven with jumper wire attached, then refer to the Troubleshooting Guide on
pages 11-8 through 11-11.
HALF-SPEED REVERSE
LIMIT SWITCH FOR 1998
VEHICLES (F&R No. 3)
ONBOARD
COMPUTER
ION:
E
TAG
Y VOL
TER
E BAT
ATIV
NEG
D
FUSE
Y
CAUT
ER
TER
PUT ICAL
S
VE BAT
COM CTR
DRI SYSTEM
RD
ER
Y
BOA TER ELE
TER
POW
ON
LES 90-88
CAR L) BAT
. by
mfd NO: 191 CLUB
CEL
G
H
(24
T
DIN
VDC
PAR
Y WIT
PEN
ONL ON 48
ENT
USE
RS
PAT
RGE
P
CHA
1.35
Ver.
COM
800
502
805
LE9
NEGATIVE BATTERY VOLTAGE!
ON BOARD COMPUTER
FUSED
mfd. by LESTER ELECTRICAL
PART NO: 19190-88
USE ONLY WITH CLUB CAR POWER DRIVE BATTERY
CHARGERS ON 48 VDC(24 CELL) BATTERY SYSTEMS
LE9805502800
Ver. 1.35 P
COM
NC
NO
M
CO
CAUTION:
NO
PATENT PENDING
NC
Figure 11-28 OBC V 1.35P
HALF-SPEED REVERSE
LIMIT SWITCH FOR 1999
VEHICLES (F&R No. 3)
Figure 11-29 F&R Limit Switch
Test Procedure 12 - Half-speed Reverse Limit Switch (F&R Limit Switch No. 3)
1. With batteries disconnected, check for proper wiring and tight connections.
2. Using a multimeter set to 200 ohms, check continuity across common (COM) and normally open (NO);
and across common (COM) and normally closed (NC) (Figures 11-29 and 11-30, Pages 11-21 and 1122). With the limit switch lever up (not depressed), readings should be:
COM to NC:
Zero (or continuity tester is illuminated)
COM to NO: Infinity (or continuity tester is not illuminated)
With the limit switch lever depressed, readings should be:
COM to NC:
Infinity (or continuity tester is not illuminated)
COM to NO: Zero (or continuity tester is illuminated)
3. If meter readings are not correct, replace limit switch.
Test Procedure 13 - Half-speed Reverse Resistor
1. Disconnect the batteries (negative cable first) and then disconnect black lead from half-speed reverse limit
switch located on Forward/Reverse switch (Figure 11-31, Page 11-22).
2. Measure resistance.
Vehicles with Multi-step Potentiometer:
2.1. Disconnect the six-pin connector (which connects the multi-step potentiometer to the Forward/
Reverse wire harness) (Figure 11-2, Page 11-3 or Figure 11-3, Page 11-4).
1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 11-21
11
11
ELECTRICAL SYSTEM AND TESTING
Circuit Testing
Test Procedure 13–Half-speed Reverse Resistor, Continued:
2.2. With multimeter set to 20K ohms, measure resistance through 18 gauge black wire from Forward/
Reverse wire harness (at disconnect from six-pin connector) to end disconnected from Half-speed
Reverse Limit Switch. Resistance should measure approximately 5100 ohms (±10%) (Figure 11-31,
Page 11-22).
SEE TEST
PROCEDURE 12,
STEP 2 FOR READING
FORWARD AND REVERSE
SWITCH
FORWARD AND REVERSE
SWITCH
-
+
WAVETEK
V
-
5XL
1000
OFF
V
500
200
+
200
20
WAVETEK
V
5XL
1000
OFF
BLACK WIRE
WITH RESISTOR
200
2m
2
200
m
20
m
200
m
2000
k
V
500
200
200k
200
20
20k
Ω
200
A
2k
BLACK WIRE
WITH RESISTOR
200
2m
2
200
m
20
m
200
m
2000
k
200k
20k
Ω
200
A
2k
V
WHITE WIRE
V
Ω
!
MAX
1000 --750V
!
COM
Ω
!
!
COM
MAX
1000 --750V
200nA
FUSED
200nA
FUSED
20K Ω SETTING
SIX-PIN CONNECTOR
200 Ω SETTING
Figure 11-30 Test Half-Speed Reverse Limit Switch
Figure 11-31 Test Half-Speed Reverse Resistor
Vehicles with Continuously Variable Potentiometer:
2.1. Disconnect the three-pin connector (connects the potentiometer to the Forward/Reverse wire harness) from the Forward/Reverse wire harness. The connector emerges from under the front body
floorboard (Figure 11-25, Page 11-18).
2.2. With a multimeter set to 20K ohms, measure the resistance through the 18 gauge black wire from the
Forward/Reverse wire harness (at disconnect from three-pin connector) to the end disconnected from
the Half-speed Reverse Limit Switch. Resistance should measure approximately 5100 ohms (±10%).
3. If the meter reading is not correct, replace the wire assembly to the limit switch.
Test Procedure 14 - Reverse Buzzer Limit Switch
1. Disconnect the battery cables (negative cable first) and then disconnect red/white wire and orange wire
from limit switch located on the F&R switch assembly.
2. Connect black (-) probe of a multimeter to top terminal of limit switch and connect red (+) probe to the bottom
terminal. With F&R switch handle in NEUTRAL or FORWARD reading should be no continuity. Place F&R
switch handle in REVERSE and reading should be continuity. If readings are not correct replace limit switch.
Test Procedure 15 - Reverse Buzzer Wire Connections
Use the following flow chart (Figure 11-32, Page 11-23) as a starting point for troubleshooting the reverse
buzzer circuit. Make sure batteries are disconnected.
1. The red 18 gauge wire should be connected to the (+) terminal of the reverse buzzer. The orange 18
gauge wire should be connected to the (-) terminal on the reverse buzzer.
Test Procedure 16 - Wire Continuity
1. Disconnect the battery cables (negative cable first) and then disconnect one end of the wire to be
tested and connect probe of multimeter to each end of the wire. Multimeter should indicate continuity. If
reading is incorrect, repair or replace wire.
Page 11-22 1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
ELECTRICAL SYSTEM AND TESTING
The Communication Display Module (CDM)
REVERSE BUZZER
WILL NOT FUNCTION
REVERSE BUZZER
WILL NOT FUNCTION AND
VEHICLE WILL NOT RUN
REVERSE BUZZER
WILL NOT FUNCTION AND
VEHICLE RUNS
CHECK BATTERIES
(TEST PROCEDURE 1)
CHECK REVERSE BUZZER
LIMIT SWITCH
(TEST PROCEDURE 14)
USE MULTIMETER
TO TEST LIMIT SWITCH
CORRECT
CONTINUITY READING
INCORRECT
CONTINUITY READING
CHECK WIRE CONNECTION
TO THE REVERSE BUZZER
(TEST PROCEDURE 15)
REPLACE LIMIT SWITCH
WIRES CORRECTLY
CONNECTED
WIRES INCORRECTLY
CONNECTED
CHECK CONTINUITY
OF CIRCUIT WIRES
(TEST PROCEDURE 16)
RECONNECT WIRES
TO REVERSE BUZZER
NO CONTINUITY
CONTINUITY
REPLACE WIRE
REPLACE REVERSE BUZZER
Figure 11-32 Reverse Buzzer Will Not Function
THE COMMUNICATION DISPLAY MODULE (CDM)
The CDM can be used to retrieve from the onboard computer four important items of information that can be
useful in troubleshooting an electric vehicle with PowerDrive System 48. To access one of these items, the
item’s corresponding Function Code must be selected on the CDM. This is done by pressing the Function
Button until the desired function code is displayed in the window. See Figure 11-33, Page 11-25 for CDM
features. Releasing the button when the desired code is displayed will display the data. Function codes and
corresponding data are as follows:
• F1 - Battery voltage:
This displays the battery pack’s current state of charge. A reading of less than 48 volts indicates the
batteries need to be charged. If a reading of less than 48 volts is obtained immediately after a charge
cycle, there may be a problem in the charge circuit.
1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 11-23
11
11
ELECTRICAL SYSTEM AND TESTING
The Communication Display Module (CDM)
CDM, Continued:
• F2 - Energy units removed since last charge cycle:
If the display reads over 75 (the vehicle Battery Trouble Light should be illuminated), the vehicle batteries need to be recharged before being used again. This data can be used to make sure all vehicles in a
fleet receive equal usage on a short term basis.
• F3 - Total accumulated energy units removed since initial vehicle start-up:
This information is useful to make sure all vehicles in a fleet receive equal usage over long periods of time.
• F4 - Last charge termination type (1 = incomplete, 2 = DVDT, 4 = normal, 8 = max. timer):
A 1, 2, 4, or 8 will be displayed.
1 - Indicates the last charge cycle was incomplete and the batteries were not fully charged. Batteries
should be charged again at the earliest opportunity.
2 - Indicates a back-up charge program was employed by the OBC to complete the charge cycle. A
DVDT charge may be displayed the first few times a new set of batteries is charged, also the first time a
set of batteries is charged after the batteries have been disconnected and reconnected. A problem may
exist if persistent DVDT readings are obtained.
4 - Indicates the last charge cycle was normal.
8 - Indicates the charger ran for sixteen hours and shut down without completing the charge cycle. This
means there may be a problem in the charge circuit.
The CDM also has a low battery signal which indicates when batteries are weak and need changing. Weak batteries in the CDM may cause CDM to register inaccurate information or no information.
USING THE CDM TO RETRIEVE DATA FROM THE ONBOARD COMPUTER
1. Turn the CDM ON.
2. Position the CDM on the seat bottom so it is aligned directly with the dash light/LED. Make sure the
CDM infra-red LED receiver is pointed at the dash light/LED, and there is a clear path between them.
NOTE
• IF, BY POSITIONING CDM ON SEAT BOTTOM CDM IS UNABLE TO COLLECT DATA STREAM
FROM OBC, HOLD CDM APPROXIMATELY 6 IN. FROM DASH LIGHT.
3. Wait approximately 30 seconds for a value to appear in the display window.
4. If a value does not appear in the display window after 30 seconds, try adjusting the aim of the CDM and
repeating step 3 until a value appears. If there is still no reading, check for weak batteries in the CDM.
Once a value has been obtained in the display window, the CDM may be removed from its receiving position
and the data reviewed. The CDM will hold the values for F1, F2, F3, and F4 until the CDM is turned OFF or it
receives another line of data. Use the following procedure to review the data stored in the CDM:
1. The value currently displayed will be F1 (battery voltage).
2. To view F2, press and hold the button on the CDM. When “Func 2” appears in the display window,
release the button. The value for F2 will then be displayed.
3. To view F3, press and hold the button on the CDM until “Func 3” appears in the display window.
Release the button. The value for F3 will be displayed.
4. To view F4, press and hold the button on the CDM until “Func 4” appears in the display window.
Release the button. The value for F4 will be displayed.
NOTE
• THE VALUES OF ALL FOUR FUNCTIONS CAN BE RECALLED BY PRESSING AND RELEASING
THE CDM BUTTON.
Page 11-24 1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
ELECTRICAL SYSTEM AND TESTING
CDM Troubleshooting Guide
LOW BATTERY
INDICATOR
DISPLAY
WINDOW
COMMUNICATION
DISPLAY MODULE
LOW
BATTERY
DISPLAY FUNCTIONS:
PRESS AND HOLD
BUTTON TO SHOW
FUNCTION NUMBER.
RELEASE BUTTON TO
SHOW FUNCTION VALUE.
Func1 Func2 Func3 Func4 -
FUNCTION
BUTTON
Battery voltage.
Energy units removed since last charge cycle.
Total accumulated energy units removed.
Last charge termination type (0 = No History
1 = Incomplete, 2 = DVDT, 4 = Normal,
8 = Max. timer).
POWER
ON
OFF
R
Club Car
PART #17075
Figure 11-33 CDM
CDM TROUBLESHOOTING GUIDE
Use this chart as a starting point for troubleshooting problems with communications between the CDM and
onboard computer. Contact your local Club Car representative for more comprehensive information.
OBC Will Not Communicate
With The CDM
Defective Dash Light
Dead CDM battery
Defective CDM unit
Defective OBC
Replace CDM battery
Replace CDM
Replace OBC
OBC program is
"locked-up"
OBC is in a
powerdown mode
Remove "+" battery
lead and discharge
the speed controller.
See the instructions in
the WARNING on
page 11-1.
After a short time,
replace the lead and
restart the OBC.
Restart OBC by
driving vehicle or by
connecting charger
DC plug
More than 75
EUs or 75% of
energy removed
from batteries
Recharge Batteries
1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 11-25
11
11
12
SECTION 12–ELECTRICAL COMPONENTS
DANGER
• BATTERY - EXPLOSIVE GASES! DO NOT SMOKE. KEEP SPARKS AND FLAMES AWAY.
VENTILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE. ALWAYS WEAR FULL
FACE SHIELD WHEN WORKING ON OR NEAR BATTERIES.
• USE EXTREME CAUTION WHEN USING TOOLS, WIRES, OR METAL OBJECTS NEAR
BATTERIES! A SHORT CIRCUIT AND (OR) SPARK COULD CAUSE AN EXPLOSION.
• BATTERY - POISON! CONTAINS ACID! CAUSES SEVERE BURNS. AVOID CONTACT WITH
SKIN, EYES, OR CLOTHING. ANTIDOTES:
- EXTERNAL: FLUSH WITH WATER. CALL A PHYSICIAN IMMEDIATELY.
- INTERNAL: DRINK LARGE QUANTITIES OF MILK OR WATER. FOLLOW WITH MILK OF
MAGNESIA OR VEGETABLE OIL. CALL A PHYSICIAN IMMEDIATELY.
- EYES: FLUSH WITH WATER FOR FIFTEEN MINUTES. CALL PHYSICIAN IMMEDIATELY.
WARNING
• ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING
EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN
GENERAL ELECTRICAL REPAIR. FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL
WARNING STATEMENTS IN THIS MANUAL.
• ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING
VEHICLE. WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES.
• TURN KEY SWITCH OFF, PLACE FORWARD/REVERSE HANDLE IN THE NEUTRAL POSITION,
AND REMOVE KEY PRIOR TO SERVICING.
• DO NOT WEAR LOOSE CLOTHING. REMOVE JEWELRY SUCH AS RINGS, WATCHES, CHAINS,
ETC. BEFORE SERVICING VEHICLE.
• ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL
CONNECTIONS.
• TO AVOID UNINTENTIONALLY STARTING THE VEHICLE, DISCONNECT BATTERIES AS SHOWN
IN FIGURE 12-1, PAGE 12-2 AND THEN DISCHARGE THE CONTROLLER AS FOLLOWS:
- TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD/REVERSE HANDLE IN THE
REVERSE POSITION.
- SLOWLY DEPRESS THE ACCELERATOR PEDAL AND KEEP IT DEPRESSED UNTIL THE
REVERSE WARNING BUZZER CAN NO LONGER BE HEARD. WHEN THE BUZZER STOPS
SOUNDING, THE CONTROLLER IS DISCHARGED.
CAUTION
• IF WIRES ARE REMOVED OR REPLACED MAKE SURE WIRING AND/OR WIRING HARNESS IS
PROPERLY ROUTED AND SECURED TO VEHICLE FRAME. FAILURE TO PROPERLY ROUTE
AND SECURE WIRING COULD RESULT IN VEHICLE MALFUNCTION, PROPERTY DAMAGE OR
PERSONAL INJURY.
1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
Page 12-1
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