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SECTION 11–ELECTRICAL SYSTEM AND TESTING

1998/1999 PowerDrive SYSTEM 48 Vehicle Maintenance and Service Supplement Page 11-111 SECTION 11 electrical SYSTEM ANDTESTINGGENERAL INFORMATIONThe PowerDrive SYSTEM 48 vehicle uses a 48-volt electrical SYSTEM that is powered by six, 8-volt lead-acidbatteries and includes an onboard computer. The PowerDrive SYSTEM 48 vehicle uses a series wound motorwhich increases or decreases the current flow (amperage) through the armature and field coils at the samerate. Vehicles that incorporate the PowerDrive SYSTEM 48 include: 1) DS electric golf car, 2) Fairway Villagerelectric, 3) Tourall electric, 4) Carryall I, II, and VI electric models, and 5) Trans-Porter, Trans-Sender andResort Villager electric models. BATTERY - EXPLOSIVE GASES!

ELECTRICAL SYSTEM AND TESTING Electrical Circuits Page 11-2 1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement 11 ELECTRICAL CIRCUITS

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Transcription of SECTION 11–ELECTRICAL SYSTEM AND TESTING

1 1998/1999 PowerDrive SYSTEM 48 Vehicle Maintenance and Service Supplement Page 11-111 SECTION 11 electrical SYSTEM ANDTESTINGGENERAL INFORMATIONThe PowerDrive SYSTEM 48 vehicle uses a 48-volt electrical SYSTEM that is powered by six, 8-volt lead-acidbatteries and includes an onboard computer. The PowerDrive SYSTEM 48 vehicle uses a series wound motorwhich increases or decreases the current flow (amperage) through the armature and field coils at the samerate. Vehicles that incorporate the PowerDrive SYSTEM 48 include: 1) DS electric golf car, 2) Fairway Villagerelectric, 3) Tourall electric, 4) Carryall I, II, and VI electric models, and 5) Trans-Porter, Trans-Sender andResort Villager electric models. BATTERY - EXPLOSIVE GASES!

2 DO NOT SMOKE. KEEP SPARKS AND FLAMES WHEN CHARGING OR USING IN AN ENCLOSED SPACE. ALWAYS WEAR FULLFACE SHIELD WHEN WORKING ON OR NEAR BATTERIES. USE EXTREME CAUTION WHEN USING TOOLS, WIRES, OR METAL OBJECTS NEARBATTERIES! A SHORT CIRCUIT AND (OR) SPARK COULD CAUSE AN EXPLOSION. BATTERY - POISON! CONTAINS ACID! CAUSES SEVERE BURNS. AVOID CONTACT WITHSKIN, EYES, OR CLOTHING. ANTIDOTES:- EXTERNAL: FLUSH WITH WATER. CALL A PHYSICIAN INTERNAL: DRINK LARGE QUANTITIES OF MILK OR WATER. FOLLOW WITH MILK OFMAGNESIA OR VEGETABLE OIL. CALL A PHYSICIAN EYES: FLUSH WITH WATER FOR FIFTEEN MINUTES. CALL PHYSICIAN IMMEDIATELY. ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE.

3 ANYONE DOINGEVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE INGENERAL electrical REPAIR. FOLLOW ALL PROCEDURES EXACTLY AND HEED ALLWARNING 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 ELECTRICALCONNECTIONS. TO AVOID UNINTENTIONALLY STARTING THE VEHICLE, DISCONNECT BATTERIES, NEGATIVECABLE FIRST, AS SHOWN IN FIGURE 11-1, PAGE 11-2, AND THEN DISCHARGE THECONTROLLER AS FOLLOWS:-TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD/REVERSE HANDLE IN THEREVERSE DEPRESS THE ACCELERATOR PEDAL AND KEEP IT DEPRESSED UNTIL THEREVERSE WARNING BUZZER CAN NO LONGER BE HEARD.

4 WHEN THE BUZZER STOPSSOUNDING, THE CONTROLLER IS SYSTEM AND TESTINGE lectrical CircuitsPage 11-2 1998/1999 PowerDrive SYSTEM 48 Vehicle Maintenance and Service Supplement11 electrical CIRCUITST here 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 buzzeris also included on every CIRCUITThe control circuit consists of:1. Key switch2. Forward/Reverse (F&R) anti-arcing limit switch3. Accelerator limit switch4. Solenoid Activating CoilPOWER CIRCUITThe power circuit consists of:1. Solid state speed controller2. Solenoid contacts3. F&R switch4. MotorSPEED CONTROL CIRCUITFor models with a multi-step potentiometer, the speed control circuit consists of the multi-step potentiometerwith discrete resistors.

5 For models equipped with a continuously variable potentiometer, the speed controlcircuit includes a solid state CIRCUITThe 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 havea charger receptacle or receptacle fuse link), and the 8-volt batteries. The onboard fuse link provides addi-tional protection to the vehicle charging circuit. The fuse is rated for use with the Club Car PowerDrivecharger only. Figure 11-1 Battery ConfigurationBATTERY BANK FOR DS, CARRYALL I, TOURALL, FAIRWAY VILLAGER 123465 BATTERY BANK FOR CARRYALL II, CARRYALL VI,RESORT VILLAGER.

6 TRANS-PORTER ANDTRANS-SENDER123465 FRONTOF VEHICLEFRONTOF VEHICLEREMOVENEGATIVECABLE FIRSTREMOVENEGATIVECABLE FIRSTDISCONNECTBATTERY CABLES HEREDISCONNECTBATTERY CABLES HEREELECTRICAL SYSTEM AND TESTINGE lectrical Circuits1998/1999 PowerDrive SYSTEM 48 Vehicle Maintenance and Service Supplement Page 11-311 Figure 11-2 Wiring Diagram - DS Electric VehicleM-B-123B+-++---++++--A1S2A2S11234 652 ORANGEGREEN/WHITERED/WHITEWHITEGREENORAN GE112 PURPLEYELLOWWHT/BLKORANGE/WHITEORANGEGRE EN/WHITE-+BLKBLACKBLACKBLACKGRAYBLUEWHIT E/ BLACKWHITE/ BLACKPURPLEYELLOWYELLOWGREENYELLOWYELLOW BROWNORANGEGREENORANGEBLUEYELLOWYELLOWBL UEBLUEREDREDBLUEWHITEWHITEORANGEREDREDRE DFUSEGRAYBLACKREDREDREDGREENGREENGREENRE DREDBLACKREDWHITEPURPLEPURPLEPURPLERED/W HITERED/WHITEBROWNBROWNGRN/WHTBLUEBLUEBL ACKBLACKBLUE3 CONTROLLERBATTERYBANKMOTORSOLENOIDFORWAR D / REVERSESWITCHLIMITSWITCHESWARNINGLIGHTRE VERSEBUZZERKEYSWITCHSIX-PINCONNECTORTHRE E-PINCONNECTORFUSE AND RECEPTACLEONBOARDCOMPUTERMULTI-STEPPOTEN TIOMETERFUSEELECTRICAL SYSTEM AND TESTINGE lectrical CircuitsPage 11-4 1998/1999 PowerDrive SYSTEM 48 Vehicle Maintenance and Service Supplement11 Figure 11-3 Wiring Diagram - Tourall.

7 Carryall IM-B-123B+-++---++++--A1S2S11234651-+23A 212A2 CONTROLLERBATTERYBANKMOTORSOLENOIDFORWAR D / REVERSESWITCHWARNINGLIGHTREVERSEBUZZERKE YSWITCHTHREE-PINCONNECTORFUSE AND RECEPTACLEONBOARDCOMPUTERMULTI-STEPPOTEN TIOMETERLIMITSWITCHESSIX PINCONNECTORWHITEGREENORANGERED/WHITEGRE EN/WHITEWHITE/ BLACKWHITEBLUEORANGEBLUEBLACKPURPLEBLUEW HITE/ BLACKREDREDGREENREDPURPLERED/WHITEORANGE BLUEWHITEYELLOWFUSEREDYELLOWYELLOWGREENB LUEREDYELLOWPURPLERED/WHITEORANGEWHITEGR EENWHITEWHITEBLUEBLACKBLACKGRAYBROWNYELL OWBLACKREDFUSEREDBLKGRAYBLACKORANGEGREEN REDBROWNBLACKPURPLEYELLOWPURPLEYELLOWWHT /BLKGRN/WHTBLUEGREENORANGE/WHITEORANGERE DBROWNGREEN/WHITEREDREDBLACKELECTRICAL SYSTEM AND TESTINGE lectrical Circuits1998/1999 PowerDrive SYSTEM 48 Vehicle Maintenance and Service Supplement Page 11-511 Figure 11-4 Wiring Diagram - Carryall II-+CCWCWSA1S2A2S1++---++++--123465 BATTERIES-M-B-123B+BLUE11223A2 FUSEMOTORSOLENOIDBLACKREDBLUEORANGEWHITE BLKREDGREENBLACKBLACKWHITEGREENORANGEGRE EN/WHITERED/WHITEBLUEWHITEORANGEFORWARD / REVERSESWITCHLIMITSWITCHESBLACKGREEN/WHI TEBROWNRED/WHITEGREENGREENORANGEBROWNYEL LOWWHT/BLKGREEN/WHITEPURPLEPURPLETHREE PIN PLUGCONTINUOUSLYVARIABLEPOTENTIOMETERBRO WNORANGE/WHITEORANGEGREENREDKEYSWITCHBLU EREVERSEBUZZERWHITE/BLACKREDREDCONTROLLE RROTATED 180 ONBOARDCOMPUTERBROWNFUSEREDYELLOWBROWNBL ACKREDBLACKGRAYBLACKBLACKYELLOWYELLOWRED /WHITEGREENPURPLEWHITEGREENWHITEREDWHITE /BLACKREDGREENGREENGRAYFUSE AND

8 RECEPTACLEGRN/WHTBLUEBLUEWARNINGLIGHTBLU EELECTRICAL SYSTEM AND TESTINGE lectrical CircuitsPage 11-6 1998/1999 PowerDrive SYSTEM 48 Vehicle Maintenance and Service Supplement11 Figure 11-5 Wiring Diagram - Carryall VI, Trans-Porter/Trans-Sender12 CCWCWSA1S2A2S1++---++++--123465-M-B-123B +11223A2 GREEN/WHITERED/WHITEORANGEBLACKMOTORBATT ERIESBLUEORANGEWHITEGREENSOLENOIDFUSEBLA CKBLUEREDCHARGERGREENREDORGBLUEBLUEWHITE ORANGEWHITEWHITEGREENYELLOWREDWHITE/BLAC KBLACKGRAYBLACKBLACKGREENREDREDREDWHITE/ BLACKCONTROLLERROTATED 180 GRN/WHTBLUEBLUEYELLOWWHT/BLKGREEN/WHITEP URPLEPURPLETHREE-PINPLUGCONTINUOUSLYVARI ABLEPOTENTIOMETERGREENORANGEBROWNBLACKBL ACKBROWNRED/WHITEGREENBLACKGREEN/WHITEBR OWNREDORANGE/WHITEORANGEGREENREDWARNINGL IGHTFRONTREVERSEBUZZERKEYSWITCHBLUEBATTE RYCONDITIONINDICATORRED/WHITEPURPLEBLACK GREENBROWNBROWNREDYELLOWYELLOWREDWHITEGR EENLIMITSWITCHESREARREVERSEBUZZERFORWARD / REVERSESWITCHBLACKON-BOARDCOMPUTERFUSEBL ACKREDELECTRICAL SYSTEM AND

9 TESTINGE lectrical Circuits1998/1999 PowerDrive SYSTEM 48 Vehicle Maintenance and Service Supplement Page 11-711 Figure 11-6 Wiring Diagram - Resort Villager-+12 CCWCWS++---++++--123465-M-B-123B+11223S2 A1S1A2A2 FUSEBLACKBLACKGREEN/WHITEBROWNRED/WHITEG REENBLACKFORWARD / REVERSESWITCHBLUEBLUEWHITEGREENORANGEBRO WNBLACKTHREE PIN PLUGBATTERYCONDITIONINDICATORBROWNREDORA NGE/WHITEORANGEGREENREDBLUEWARNINGLIGHTR EVERSEBUZZERKEYSWITCHCONTINUOUSLYVARIABL EPOTENTIOMETERGRN/WHTBLUEBLUERED/WHITEGR EENPURPLEBLACKCONTROLLERROTATED 180 ONBOARDCOMPUTERBROWNBROWNREDYELLOWBLACKG RAYYELLOWREDBLACKBLACKYELLOWREDWHITE/BLA CKWHITEGREENWHITEGREENREDREDREDWHITE/BLA CKSOLENOIDBLUEWHITEGREENREDMOTORBLACKBAT TERIESWHITEORANGEREARREVERSEBUZZERREDBLK BLACKFUSEFUSE AND RECEPTACLEREDGRAYGREENBLACKORANGEGREENRE D/WHITELIMITSWITCHESORANGEGREEN/WHITEYEL LOWWHT/BLKGREEN/WHITEPURPLEPURPLEELECTRI CAL SYSTEM AND TESTINGT roubleshooting GuidePage 11-8 1998/1999 PowerDrive SYSTEM 48 Vehicle Maintenance and Service Supplement11 TROUBLESHOOTING GUIDEDIAGNOSTIC REFERENCE CHARTSUse these charts as a starting point for SYSTEM troubleshooting.

10 More detailed SYSTEM TESTING instruc-tions follow. Figure 11-7 Battery Warning Diagnostic ChartBattery Warning LightIn Dash Is IlluminatedCharge ran16 hoursRecharge batteriesCheck batteries ( SECTION 13)Check charger ( SECTION 14)Check OBC (Page 11-20)OBC is defectiveReplace OBCNo AC presentLightremains onLight comes onintermittentlywhen vehicleis in use andwhen it isstoppedRestore will goout and charge will resumeLightremains onGlows for10 secondsBatteries didnot receiveadequatechargeBatteries didnot receive fullcharge, butmay be usedMore than 75 EUs or 75% ofenergy removedfrom batteriesCheck function2 on CDMOpen circuit(no load)battery voltagebelow 48 voltsDC plug isdisconnectedCharge interrupt(DC cord dis-connectedduring chargecycle)


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