2004 Club Car Turf 1 2 6 Carryall 1 2 6 Plus XRT Gasoline and Electric Vehicle Repair Manual

Club Car MANUAL NUMBER 102397605 EDITION CODE 1203A00000 POWERDRIVE SYSTEM 48 ELECTRIC VEHICLES 200 4 MAINTENANCE SERVICE SUPPLEMENT

2004 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 the following: 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. It is the policy of Club Car, Inc. to assist its distributors and dealers in continually updating their service knowledge and facilities so they can provide prompt and efﬁcient service for vehicle owners. Regional technical rep- resentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and other service publications also represent Club Car’s continuing commitment to customer support. 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 supplement, 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 Technical Service Representative at (706) 863-3000, ext. 3580. This supplement does not contain maintenance and service procedures for the battery charger. Contact your local Club Car representative for information on how to obtain the appropriate battery charger maintenance and service manual. 2004 DS Golf Car Maintenance & Service Manual Publication Part No. 102397601 2004 Turf/Carryall Vehicle Maintenance & Service Manual Publication Part No. 102397602 2004 Transportation Vehicle Maintenance & Service Manual Publication Part No. 102397603 Copyright © 2003 Club Car, Inc. Club Car, Carryall, and PowerDrive are registered trademarks of Club Car, Inc. This manual effective July 28, 2003.

Page ii 2004 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.

2004 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page iii CONTENTS SECTION 10 – PERIODIC MAINTENANCE General Warning ............................................................................................................................... 10-1 General Information .......................................................................................................................... 10-3 Periodic Service Schedule ................................................................................................................ 10-3 Periodic Lubrication Schedule .......................................................................................................... 10-5 SECTION 11 – ELECTRICAL SYSTEM AND TESTING General Information .......................................................................................................................... 11-1 Electrical Circuits .............................................................................................................................. 11-1 Control Circuit ............................................................................................................................... 11-1 Power Circuit ................................................................................................................................ 11-1 Throttle Input Device Circuit ......................................................................................................... 11-2 Charge Circuit ............................................................................................................................... 11-2 Wiring Diagrams ............................................................................................................................... 11-3 Diagnostic Flow Chart ....................................................................................................................... 11-13 Battery Warning Light ................................................................................................................... 11-13 Troubleshooting Guide ..................................................................................................................... 11-14 Test Procedures ............................................................................................................................... 11-17 Index of Test Procedures .............................................................................................................. 11-17 Communication Display Module (CDM) ............................................................................................ 11-48 Using the CDM to Retrieve Data from the Onboard Computer .................................................... 11-49 CDM Troubleshooting Guide ........................................................................................................ 11-50 SECTION 12 – ELECTRICAL COMPONENTS Key Switch ........................................................................................................................................ 12-1 Battery Condition Indicator ............................................................................................................... 12-3 Forward/Reverse Switch ................................................................................................................... 12-3 Forward/Reverse Limit Switches .................................................................................................. 12-5 Half-Speed Resistor – to Half-Speed Reverse Limit Switch ......................................................... 12-6 Reverse Buzzer ................................................................................................................................ 12-7 Solenoid ............................................................................................................................................ 12-8 Diode – Solenoid .......................................................................................................................... 12-9 Resistor – Solenoid ....................................................................................................................... 12-10 Onboard Computer (OBC) ................................................................................................................ 12-11 Solid State Speed Controller ............................................................................................................ 12-13

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2004 Club Car Turf 1 2 6 Carryall 1 2 6 Plus XRT Gasoline and Electric Vehicle Repair Manual

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