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

 ................
................

In order to avoid copyright disputes, this page is only a partial summary.

Google Online Preview   Download