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TransPorter 6
Club Car TransPorter 6 Maintenance And Service Manual
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2019
T
ransporter
Maintenance
and
Service
Manual
Electric
V
ehicle
with
QuiQ
™
™
™
Charger
Manual
Number
1053551
14
Edition
Code
B
2
Table of Contents
Table of Contents
5
SECTION 1 - Safety
13
Safety Details
13
Personal Safety
13
Machine Safety
13
Information
13
General Warnings
14
Disabling the Vehicle
15
Disconnecting the Batteries - Electric Vehicles
15
Connecting the Batteries - Electric Vehicles
16
Recycling Lead-Acid Batteries
16
International Safety Symbols on Batteries
17
SECTION 2 - Vehicle Specifications
19
Vehicle Specifications
19
Quiq Battery Charger Specifications
21
SECTION 3 - General Information
23
Model Identification
23
Storing the Vehicle
24
Preparing the Vehicle for Extended Storage
24
Returning the Stored Vehicle to Service
25
SECTION 4 - Body and Trim
27
Cleaning the Vehicle
27
Seat Cleaning
27
Front Body Repair
28
Light Scratches
28
Abrasions and Haze
28
Large Scratches and Abrasions
28
Front Body
28
Brushguard Removal
28
Brushguard Installation
29
Cowl Removal
30
Cowl Installation
30
Grille Removal
32
Grille Installation
32
Front Bumper and Side Fender Removal
34
Front Bumper and Side Fender Installation
34
Instrument Panel Removal
35
Instrument Panel Installation
35
Dash Removal
36
Dash Installation
36
Tilt Bed
38
Tilt Bed Removal
38
Tilt Bed Installation
38
Bed Latch Assembly Removal
40
Bed Latch Assembly Installation
40
Rear Fenders and Tailskirt
42
Rear Fender and Tailskirt Removal
43
Rear Fender and Tailskirt Installation
43
Rear Triangle Reflector
44
Rear Triangle Reflector Removal
44
Rear Triangle Reflector Installation
44
Electric Bed Lift
46
Electric Bed Lift Removal
47
Electric Bed Lift Installation
47
Floor Mat
48
Floor Mat Removal
48
Floor Mat Installation
48
Rear-Facing Seat
49
Trailer Hitch
50
Trailer Hitch Removal
50
Trailer Hitch Installation
50
Electrolyte Tray
51
Electrolyte Tray Removal
52
Electrolyte Tray Installation
52
SECTION 5 - Accelerator and Brake Pedal Group
53
Brake Pedal and Park Brake
53
Brake Pedal Removal
53
Brake Pedal Installation
54
Park Brake Removal
56
Park Brake Installation
57
Accelerator Pedal - Electric Vehicles
58
Accelerator Pedal Removal - Electric Vehicles
59
Accelerator Pedal Installation - Electric Vehicles
59
Pedal Group Adjustment - Electric Vehicles
60
SECTION 6 - Brake System
65
General Information
65
Brake Shoe Removal
65
Brake Assembly Cleaning
67
Brake Shoe Installation
70
Brake Adjustment
71
Brake Cluster Adjustment
72
Brake Cable Equalization
74
Final Brake Cluster Adjustment
75
Test Drive Vehicle
75
Brake Cluster Removal and Installation
76
Front Brake Cluster Removal
76
Front Brake Cluster Installation
76
Rear Brake Cluster Removal
78
Rear Brake Cluster Installation
78
Front Brake Cables
79
Front Brake Cable Removal
80
Front Brake Cable Installation
80
Rear Brake Cables
81
Rear Brake Cable Removal
82
Rear Brake Cable Installation
82
Emergency Brake System
83
Emergency Brake Removal
83
Emergency Brake Installation
84
Emergency Brake Adjustment
84
SECTION 7 - Steering and Front Suspension
87
General Information
87
Steering Wheel
87
Steering Wheel Removal
87
Steering Wheel Installation
88
Steering Column
89
Steering Column Removal
90
Steering Column Disassembly
90
Steering Column Assembly
90
Steering Column Installation
91
Steering Adjustment
92
Rack and Pinion
93
Rack and Pinion Inspection
93
Rack and Pinion Removal
93
Rack and Pinion Disassembly
94
Rack and Pinion Assembly
96
Rack and Pinion Installation
99
Tie Rod and Drag Link
100
Tie Rod and Drag Link Removal
100
Tie Rod and Drag Link Installation
100
Front Suspension
101
Lubrication
101
Wheel Alignment
101
Front Suspension Components
103
Leaf Spring Removal
103
Leaf Spring Installation
103
Kingpin and Steering Spindle Removal
103
Kingpin and Steering Spindle Installation
106
Delta A-Plate Removal
106
Delta A-Plate Installation
106
Shock Absorber Removal
106
Shock Absorber Installation
106
Front Wheel Bearings and Hubs
107
Front Wheel Free Play Inspection
107
Front Hub and Wheel Bearings Removal
107
Front Hub and Wheel Bearings Installation
108
SECTION 8 - Wheels and Tires
109
General Information
109
Wheels
109
Wheel Removal
109
Wheel Installation
109
Tires
110
Tire Removal
110
Tire Repair
110
Tire Installation
111
SECTION 9 - Rear Suspension
113
General Information
113
Shock Absorbers
113
Shock Absorber Inspection and Removal
113
Shock Absorber Installation
113
Multi-Leaf Springs
114
Multi-Leaf Spring Removal
114
Multi-Leaf Spring Installation
115
SECTION 10 - Periodic Maintenance
117
General Information
117
Pre-Operation and Daily Safety Checklist
117
Performance Inspection
117
Maintenance
118
Periodic Service Schedules
119
Periodic Lubrication Schedules
122
SECTION 11 - Controller Diagnostic Tool (CDT)
123
General Information
124
Features
124
Plugging the CDT into the Vehicle
124
Introductory Display
125
Quick Reference Guide - IQ Plus with Quiq Charger
126
System Info
127
Model Number
127
Amp Hours Display
138
Lin
138
Diagnostics Menu
139
Present Errors Folder
139
Fault History Folder
139
System Faults
139
Fault Recovery
141
Fault Descriptions
142
Throttle Fault 1
142
02 Low Battery Voltage
142
03 Overvoltage
142
04 Thermal Cutback
142
06 Hpd
142
07 Main Welded
142
08 Relay Welded
142
09 Speed Sensor
142
10 Main Driver on
142
12 Main Dropout
143
13 Motor Stall
143
14 Main Driver off
143
15 Relay Dnc
143
16 Keyswitch Sro
143
17 Current Sense
143
18 M- Shorted
143
20 Driver Overcurrent
143
21 Precharge Fault
143
22 Field Missing
143
25 Incorrect Password
144
26 Circuit Brkr Open
144
27 Max Password Tries
144
29 Relay Drvr off
144
30 Relay Coil Fault
144
Anti-Tamper Fault
144
Lockout Fault
144
Low SOC
144
Main CONT DNC
145
Main Coil Fault
145
Proc/Wiring
145
Open Armature
145
Incorrect Password (OEM Access Level Only)
145
Fault History
145
Clearing Fault History
145
Programming
146
Cloning
146
Favorites
146
HHP Settings
147
Plot & Log
148
Plot
148
Log
148
CDT Troubleshooting
149
Connection Tests
150
SECTION 12 - Electrical System Troubleshooting
153
General Information
153
Accessories
153
Charge Indicator Light
153
Features
153
Sonic Weld, Diode, and 10K Ohm Resistor Locations
156
Troubleshooting
157
Troubleshooting the Vehicle with the CDT
157
Troubleshooting Guide 1
161
Troubleshooting Guide 2
161
Test Procedures
163
Testing Basics
163
SECTION 13 - Electrical Components
195
Key Switch
195
Testing the Key Switch
195
Key Switch Removal
195
Key Switch Installation
195
Forward/Reverse Rocker Switch
196
Forward/Reverse Rocker Switch Removal
196
Forward/Reverse Rocker Switch Installation
196
Run/Tow Switch
197
Run/Tow Switch Removal
197
Run/Tow Switch Installation
197
Circuit Breaker
198
Circuit Breaker Removal
198
Circuit Breaker Installation
198
Motor Controller Output Regulator (MCOR)
199
Testing the MCOR
199
MCOR Removal
199
MCOR Installation
199
Reverse Buzzer
200
Reverse Buzzer Removal
200
Reverse Buzzer Installation
200
Speed Controller Cover
200
Removing the Speed Controller Cover
200
Installing the Speed Controller Cover
200
Solenoid
201
Solenoid Removal
201
Solenoid Installation
201
Speed Controller
202
Speed Controller Removal
202
Speed Controller Installation
202
Charge Indicator Light
204
Testing the Charge Indicator Light
204
Charge Indicator Light Removal
204
Charge Indicator Light Installation
204
Emergency Stop Switch
204
Testing the Emergency Stop Switch
204
Emergency Stop Switch Removal
204
Emergency Stop Switch Installation
205
Headlights
206
Headlight Bezel Removal
206
Headlight Bezel Installation
206
Halogen Headlight Bulb Removal
207
Halogen Headlight Bulb Installation
207
Halogen Headlight Lens Removal
208
Halogen Headlight Lens Installation
208
LED Headlight Removal
209
LED Headlight Installation
209
Lockout Relay
209
Lockout Relay Removal
210
Lockout Relay Installation
210
Walk Away Relay
211
Walk Away Relay Removal
211
Walk Away Relay Installation
211
SECTION 14 - Batteries
213
General Information
213
Battery Testing Basics - 6 Volt
214
Observation
214
Measuring Voltage of Battery Set
214
Battery Cell Numbering
214
Battery Testing - 6 Volt
215
Battery Regrouping
215
Battery Replacement
217
Battery Care
218
Water Quality
218
Deionizer
219
Battery Care - Vehicles Equipped with the Single-Point Watering System (SPWS)
220
Battery Care - Vehicles Without the Single-Point Watering System (SPWS)
221
Self-Discharge
222
Electrolyte Level
222
Vibration Damage
223
Single Point Watering System (SPWS)
223
Initial Maintenance of the SPWS
223
Watering Batteries with the SPWS
223
Battery Storage
225
Fleet Rotation
225
Deep-Discharge
226
Early Excessive Discharging
226
SECTION 15 - Battery Charger
227
General Information
227
Features
227
UL and CSA Listing
227
CE Compliance
227
IP (Ingress Protection) Rating
227
How to Identify Charge Algorithm Number
228
How to Change the Algorithm
229
The Charge Circuit
229
Onboard Charger Operation
230
Charger Displays
232
AC Power Connection
234
Charging Batteries
234
Maintenance
235
Troubleshooting
236
Test Procedures
237
Charger Repairs
238
Onboard Charger Removal and Installation
238
Onboard Charger Removal
238
Onboard Charger Installation
239
SECTION 16 - Motor
241
General Information
241
External Motor Testing
241
Motor Removal
243
Motor Disassembly
245
Motor Component Testing and Inspection
247
Armature Inspection and Testing
247
Motor Frame and Field Windings Inspection
248
Motor Brush, Spring, and Terminal Insulator Inspection
248
Reconditioning the Motor
251
Motor Specifications
251
Motor Assembly
251
Motor Installation
253
SECTION 17 - Transaxle
257
Lubrication
257
Axle Bearing and Shaft
257
Axle Shaft
257
Axle Bearing
260
Transaxle
261
Transaxle Removal
261
Transaxle Disassembly, Inspection, and Assembly
264
Transaxle Disassembly and Inspection
264
Transaxle Assembly
266
Transaxle Installation
267
SECTION 18 - Wiring Diagrams
269
General Information
270
Index
277
Other manuals for Club Car TransPorter 6
Owner's Manual
80 pages
Maintenance Service Manual
132 pages
4
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Club Car TransPorter 6 Specifications
General
Brand
Club Car
Model
TransPorter 6
Category
Electric Vehicles
Language
English
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