SECTION 11–ELECTRICAL SYSTEM AND TESTING
SECTION 11?ELECTRICAL SYSTEM AND
11
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
Electrical Circuits
BATTERY BANK FOR DS, CARRYALL I, TOURALL,
2
FAIRWAY VILLAGER
FRONT
3
OF VEHICLE 4
5
BATTERY BANK FOR CARRYALL II, CARRYALL VI, RESORT VILLAGER, TRANS-PORTER AND TRANS-SENDER
FRONT
3 5
OF VEHICLE
1
1
6
REMOVE NEGATIVE CABLE FIRST
REMOVE NEGATIVE CABLE FIRST
6
DISCONNECT BATTERY CABLES HERE
2 4
DISCONNECT BATTERY CABLES HERE
Figure 11-1 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
11 Electrical Circuits
ORANGE BLUE WHITE
GREEN BROWN ORRAENDOGREANGE/WHITE
2 1
REVERSE BUZZER
WARNING LIGHT
BLUE
KEY SWITCH
MULTI-STEP POTENTIOMETER
GRN/YEWWLHHLTTO/BWLBLKUE
PURPLE
SIX-PIN CONNECTOR
GREREOENRDANGBEROWN
GPRUEREPYNLBEE/LWLALHCOKITWE
FUSE AND RECEPTACLE
BLK
+
RED
BATTERY BANK
+ -
+
5
-
6
BLACK GRAY FUSE
+ -
2
+ -
+
-
3
4
RED RED
+ -
1
THREE-PIN CONNECTOR
FUSE
BLACK
ONBOARD COMPUTER
GREEN
BLUE YELLOW YELLOW RED BROWN BLACK GRAY
FORWARD / REVERSE SWITCH
BLUE
BOLUREANGE WHITE LIMIT
WHGITREE/EBNL/AWCHKITREEODR/WANH1GIGTEREEESNWWIHT2ICTEHES 3
BLACK PURPLE
BLUE
RED/WHITE PURPLE
WHITE/ BLACK
RED
GREEN RERDED
YELLOW SOLENOID
RED
YELLOW
3 21 M- B-
RED CONTROLLER
B+
PURRYEPDELL/EWLOHWITE WHITEBLUE
GREEN
A2
ORANGE
S2
A1
S1 MOTOR
BLACK BLACK
Figure 11-2 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
ORANGE
BLUE WHITE
BLK GRNY/EWWLHLHTTO/BWLK
GREEN BROWN ORRAENDOGREANGE/WHITE
2 1
REVERSE BUZZER
WARNING LIGHT
KEY SWITCH
MULTI-STEP POTENTIOMETER
BLUE
PURPLE
SIX PIN CONNECTOR
GREREOENRDANGBEROWN
GPRUEREPYNLBEE/LWLALHCOKITWE
FUSE AND RECEPTACLE
+
RED
BATTERY BANK
+ -
+
5
-
6
BLACK GRAY FUSE
+ -
2
+ -
+
-
3
4
RED RED
+ -
1
THREE-PIN CONNECTOR
BLACK
ONBOARD COMPUTER
GREEN
BLUE YELLOW YELLOW
RED BROWN
BLACK GRAY
FORWARD / REVERSE SWITCH
BLUE
BOLUREANGE
LIMIWT HITE
SWITCHES
WGHRITEEE/ NB/LWAHCRIKETOEDR/WANHGITGEE1REEN
2
WHITE
3
BLACK PURPLE
BLUE
RED/WHITE PURPLE
WHITE/ BLACK
RED
GREEN RERDED
YELLOW SOLENOID
RED
YELLOW
3 21
MB-
RED CONTROLLER
A2 B+
WHITE WHITGEREEN FUSE
PURRYEPDELL/EWLOHWITE WHITE BLUE
ORANGE
A2
S2 A1
S1 MOTOR
BLACK BLACK
Figure 11-3 Wiring Diagram - Tourall, Carryall I
Page 11-4 1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
ELECTRICAL SYSTEM AND TESTING
11 Electrical Circuits
BROWN
BROWN ORANGE GREEN
YELLOW RED
BLUE
GREEN RED
KEY SWITCH 2
1
ORAONRGAENGE/WHITE
REVERSE BUZZER
BROWN
WARNING LIGHT
BLUE
GRN/BWLHUTE
CW
CONTINUOUSLY
VARIABLE
CCW
POTENTIOMETER
S THREE
PINWYHETLPL/UBORGLWKPRLEEEN/WHITE
PLUG
BROWN
ONBOARD COMPUTER
GREEN
PURPLE RED/WHITE
FUSE
BLACK
GBRLEABECRNKRO/GWEWRDHEN/IWTEENHITE FORWARD / REVERSE SWITCH
BBLLUE
ORANGE
3 21
M-
B-
CONTROLLER ROTATED 180?
A2 WHWITHEITGEREEN
B+ YELLOW
BLACK BLACK
BLACK
GRAY
RED
YELLOW
BLK RED
WHITE/BLACK
BLACK
FUSE AND RECEPTACLE
BLUE WHITE
LIMIT SWITCHES
1
GREEN/WHITE
RED/WHITE
2
3
ORANGE
GREEN
WHITE
BLACK
RED
WHITE/BLACK RED
GREEN RED
BOLUREANWGHEITE
GRAY +
RED GREEN
FUSE
BLACK
+ -
5
+ -
3 + -
+ -
2
+ 1
S2
+
4
RED
GREEN
SOLENOID
A2
A1 S1
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
BLUE
BLACK BROWN ORANGE GREEN
BROWN
YELLOW RED
GREERNED
BATTERY
CONDITION INDICATOR
OORRAANNGGEE/WHITE RED BROWN
1 2
WARNING
LIGHT
BLUE
GRNB/WLUHET
CW
2 1
FRONT REVERSE BUZZER
KEY SWITCH
CONTINUOUSLY VARIABLE POTENTIOMETER
BROWN
ON-BOARD COMPUTER
CCW
S
WHYTE/BLPLLUKORGWPRLEEEN/WHITE
THREE-PIN
PLUG
GBBRLLEAABECCRNKKRO/GWEWRDHEN/IWTEENHITE FORWARD / REVERSE SWITCH
BLUE ORANGE
BLACK
BLUE WHITE
LIMIT SWITCHES
1
GREEN/WHITE
RED/WHITE
ORANGE
GREEN
2
WHITE
GREEN
RED/WHBILTAPECUKRPLE
3 21
M-
B-
CONTROLLER ROTATED 180?
A2 WHITEWHITGEREEN
B+
BLACK
BLACK
YELLOW
RED WHITE/BLACK
BLACK
FUSE
BLACK GRAY
RED YELLOW
GREEN
REDRED RED WHITE/BLACK
3
RED
BLUOERANGWEHITEGREEN
SOLENOID
REAR
REVERSE BUZZER
ORG RED
GREEN
CHARGER
BLACK
RED BLUE BLACK
FUSE
+ -
5 -
+
+ -
3 + -
4
+ -
2
6 BATTERIES
+ 1
S2
A2
A1 S1 MOTOR
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
11 Electrical Circuits
BLUE
BLACK BROWN ORANGE GREEN
BROWN
YELLOW RED
BATTERY
CONDITION INDICATOR
GREERNED
OORRAANNGGEE/WHITE RED BROWN
2 1
REVERSE BUZZER
KEY SWITCH
1 2
WARNING
LIGHT
BLUE
GRNB/WLUHET
CONTINUOUSLY VARIABLE POTENTIOMETER
CW
BROWN
ONBOARD COMPUTER
CCW
S
WHYTE/BLPLLUKORGWPRLEEEN/WHITE
THREE PIN
PLUG
GBBRLLEAABECCRNKKRO/GWEWRDHEN/IWTEENHITE FORWARD / REVERSE SWITCH
BLUE
GREEN
RED/WHBILTAPECUKRPLE
FUSE
BLACK
3 21
M-
B-
A2 B+
WHITEWHITGEREEN
CONTROLLER ROTATED 180?
BLACK BLACK
YELLOW
BLACK GRAY
RED YELLOW
BLK RED RED
WHITE/BLACK
FUSE AND BLACK RECEPTACLE
BLUE WHITE
LIMIT SWITCHES
1
GREEN/WHITE
RED/WHITE
2 3
ORANGE
GREEN
WHITE
BLACK
GRAY FUSE
+
RED
GREEN
BLACK ORANGE
+ -
5 -
+
RED WHITE/BLACK
RED GREEN
RED
BLUOERANGWEHITGEREEN
SOLENOID
+ -
3 + -
+ -
2
4
+ -
1
A2
S2 A1
S1
REAR REVERSE
RED
BUZZER
6 BATTERIES
MOTOR
Figure 11-6 Wiring Diagram - Resort Villager
1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 11-7
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
No AC present
Restore AC power.
Light will go out and charge
will resume
Light remains on
Check function 2 on CDM
Light comes on intermittently when vehicle is in use and when it is stopped
More than 75 EUs or 75% of energy removed from batteries
Open circuit (no load)
battery voltage below 48 volts
Charge ran 16 hours
Charge interrupt (DC cord disconnected during charge cycle)
Glows for 10 seconds
Light remains on
Batteries did not receive full
charge, but may be used
Batteries did not receive adequate
charge
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
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