2001-2002 Club Car DS Powerdrive Vglide 36 48 IQ Electric Golf Cart Repair Manual

POWERDRIVE SYSTEM 48 VEHICLES MANUAL NUMBER 102190005 EDITION CODE 0502C00000 2001-2002 MAINTENANCE SERVICE SUPPLEMENT

2001/2002 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page i FOREWORD Club Car vehicles are designed and built to provide the ultimate in performance efﬁciency; however, proper maintenance and repair are essential for achieving maximum service life and continued safe and reliable operation. This supplement provides detailed information for the maintenance and repair of PowerDrive System 48 electric vehicles and should be used in conjunction with the appropriate maintenance and service manual. If you do not have the appropriate maintenance and service manual, you may order one from your local Club Car or Carryall representative. Maintenance and service manuals available include: This supplement and corresponding maintenance and service manual should be thoroughly reviewed prior to servicing the vehicle. The procedures provided must be properly implemented, and the DANGER, WARNING, and CAUTION statements must be heeded. This supplement was written for the trained technician who already has knowledge and skills in electrical and mechanical repair. If the technician does not have such knowledge and skills, attempted service or repairs to the vehicle may render the vehicle unsafe. For this reason, Club Car advises that all repairs and/or service be performed by an authorized Club Car or Carryall distributor/dealer representative or by a Club Car factory- trained technician. This service supplement, used in conjunction with the appropriate maintenance and service manual, covers all aspects of typical vehicle service; however, unique situations do sometimes occur when servicing a vehicle. If it appears that a service question is not answered in this manual, you may write to us at: Club Car, Inc., P.O. Box 204658, Augusta, GA 30917-4658, USA, Attention: Technical Services, or contact a Club Car Tech- nical Service Representative at (706) 863-3000, ext. 3580. 2001/2002 DS Golf Car Maintenance & Service Manual Publication Part No. 102190001 2001/2002 Turf/Carryall Vehicle Maintenance & Service Manual Publication Part No. 102190002 2001/2002 Transportation Vehicle Maintenance & Service Manual Publication Part No. 102190003 Copyright © 2002 Club Car, Inc. Club Car, Carryall, and PowerDrive are registered trademarks of Club Car, Inc. This manual effective July 24, 2000.

Page ii 2001/2002 PowerDrive System 48 Vehicle Maintenance and Service Supplement ∆ WARNING • Read Section 1 – Safety in the appropriate maintenance and service manual before attempting any service on the vehicle. • Before servicing vehicle, read complete section(s) and any referenced information that may be relevant to the service or repair to be performed. NOTE: This manual represents the most current information at the time of publication. Club Car, Inc. is continually working to further improve its vehicles and other products. These improvements may affect servicing procedures. Any modification and/or significant change in specifications or procedures will be forwarded to all Club Car distributors/dealers and will, when applicable, appear in future editions of this manual. Club Car, Inc. reserves the right to change specifications and designs at any time without notice and without the obligation of making changes to units previously sold. There are no warranties expressed or implied in this supplement. See the limited warranty found in the vehicle owner’s manual or write to: Club Car, Inc., P.O. Box 204658, Augusta, GA 30917-4658, USA, Attention: Warranty Administration.

2001/2002 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page iii CONTENTS SECTION 10 – PERIODIC MAINTENANCE General Information .......................................................................................................................... 10-2 Throttle Input Device Identification ................................................................................................... 10-3 Pre-Operation and Daily Safety Checklist ........................................................................................ 10-4 Performance Inspection ................................................................................................................ 10-5 Periodic Service Schedule ................................................................................................................ 10-5 Periodic Lubrication Schedule .......................................................................................................... 10-7 SECTION 11 – ELECTRICAL SYSTEM AND TESTING General Information .......................................................................................................................... 11-2 Solenoid Identification ...................................................................................................................... 11-2 Electrical Circuits .............................................................................................................................. 11-3 Control Circuit ............................................................................................................................... 11-3 Power Circuit ................................................................................................................................ 11-3 Throttle Input Device Circuit ......................................................................................................... 11-3 Charge Circuit ............................................................................................................................... 11-3 Wiring Diagrams ............................................................................................................................... 11-4 Diagnostic Flow Chart ....................................................................................................................... 11-14 Battery Warning Light ................................................................................................................... 11-14 Troubleshooting Guide ..................................................................................................................... 11-15 Test Procedures ............................................................................................................................... 11-18 Index of Test Procedures .............................................................................................................. 11-18 Communication Display Module (CDM) ............................................................................................ 11-55 Using the CDM to Retrieve Data from the Onboard Computer .................................................... 11-56 CDM Troubleshooting Guide ............................................................................................................ 11-57 SECTION 12 – ELECTRICAL COMPONENTS Key Switch ........................................................................................................................................ 12-2 Battery Condition Indicator ............................................................................................................... 12-4 Forward/Reverse Switch ................................................................................................................... 12-5 Forward/Reverse Limit Switches .................................................................................................. 12-6 Half-Speed Resistor – to Half-Speed Reverse Limit Switch ......................................................... 12-8 Accelerator Pedal Limit Switch ......................................................................................................... 12-9 Reverse Buzzer ................................................................................................................................ 12-10

2001-2002 Club Car DS Powerdrive Vglide 36 48 IQ Electric Golf Cart Repair Manual

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