2001-2002 Club Car PowerDrive System 48 Maintenance And Service Manual Supplement

Description

This Official 2001-2002 Club Car PowerDrive System 48 Maintenance And Service Manual Supplement provides detailed service information, step-by-step repair instruction and maintenance specifications 2001-2002 Club Car PowerDrive System 48 Electric motors.

Please note that this supplement need corresponding manual below for different Golf Car application:

2001-2002 Club Car DS Golf Car Maintenance And Service Manual, item# 102190001

2001-2002 Club Car Turf Carryall Maintenance And Service Manual, item# 102190002

2001-2002 Club Car DS Transportation Maintenance And Service Manual, item# 102190003

2001-2002 Club Car PowerDrive System 48 Maintenance And Service Manual Supplement Table of Contents

SECTION 10 – PERIODIC MAINTENANCE
General Information
Throttle Input Device Identification
Pre-Operation and Daily Safety Checklist
Performance Inspection
Periodic Service Schedule
Periodic Lubrication Schedule

SECTION 11 – ELECTRICAL SYSTEM AND TESTING
General Information
Solenoid Identification
Electrical Circuits
Control Circuit
Power Circuit
Throttle Input Device Circuit
Charge Circuit
Wiring Diagrams
Diagnostic Flow Chart
Battery Warning Light
Troubleshooting Guide
Test Procedures
Index of Test Procedures
Communication Display Module (CDM)
Using the CDM to Retrieve Data from the Onboard Computer
CDM Troubleshooting Guide

SECTION 12 – ELECTRICAL COMPONENTS
Key Switch
Battery Condition Indicator
Forward/Reverse Switch
Forward/Reverse Limit Switches
Half-Speed Resistor – to Half-Speed Reverse Limit Switch
Accelerator Pedal Limit Switch
Reverse Buzzer
Solenoid
Diode – Solenoid
Resistor – Solenoid
Onboard Computer (OBC)
Solid State Speed Controller
Charger Receptacle
Receptacle Fuse Link
Continuously-Variable Potentiometer
Multi-Step Potentiometer
Resistors
Motor Controller Output Regulator (MCOR)
Voltage Limiter
Brake Pedal Limit Switch
Park Brake Pedal Limit Switch
Brake Light Relay
Light Switch
Battery Warning Light
Horn
Horn Switch

SECTION 13 – BATTERIES
General Information
Common Misconceptions About Batteries
Battery Replacement
Battery Care
Preventive Maintenance
Self-Discharge
Electrolyte Level
Mineral Content
Vibration Damage
Battery Charging
Charger Shuts Off After 16 Hours
Deep-Discharge
Early Excessive Discharging
Incoming AC Service
Fleet Rotation
Numbering Vehicles and Chargers
Battery Troubleshooting Chart
Battery Testing
Battery Charger Test
On-Charge Voltage Test
Hydrometer Test
Discharge Test
Battery Troubleshooting Examples
Battery Storage
Charging a Battery Pack that has Low Voltage

SECTION 14 – POWERDRIVE BATTERY CHARGER
Refer to the appropriate battery charger maintenance and service manual

SECTION 15-MOTOR
General Information
External Motor Testing
Motor
Motor Component Testing and Inspection
Armature
Field Windings Inspection
Motor Components
Bearing Inspection
Bearing Removal
Bearing Installation
Reconditioning the Motor
Motor Assembly
Motor Installation

SECTION 16A – TRANSAXLE (TYPE G)
Transaxle Identification
Lubrication
Axle Bearing and Shaft
Axle Shaft
Axle Bearing
Transaxle
Transaxle Removal
Transaxle Disassembly, Inspection, and Assembly
Transaxle Disassembly and Inspection
Transaxle Assembly
Transaxle Installation

SECTION 16A – TRANSAXLE (TYPE K)
Transaxle Identification
Lubrication
Axle Bearing and Shaft
Axle Shaft
Axle Bearing
Transaxle
Transaxle Removal
Transaxle Disassembly, Inspection, and Assembly
Transaxle Disassembly and Inspection
Transaxle Assembly
Shimming the Transaxle
Transaxle Installation

SECTION i – INDEX