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Club Car 2009-20011 Electric Precedent Maintenance And Service Manual

Iq system and excel system vehicles
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Table of Contents

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2009-2011 Electric Precedent
Maintenance and
Service Manual
IQ System and Excel System Vehicles
Manual Number 103472701
Edition Code 0309C1110B

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Summary of Contents for Club Car 2009-20011 Electric Precedent

  • Page 1 2009-2011 Electric Precedent Maintenance and Service Manual IQ System and Excel System Vehicles Manual Number 103472701 Edition Code 0309C1110B...
  • Page 3 If it appears that a service question is not answered in this manual, please contact your nearest authorized Club Car dealer or distributor for assistance. You may also write to us at: Club Car, LLC, P.O. Box 204658; Augusta, GA 30917–4658 USA, Attention: Technical Services.

  • Page 5: Table Of Contents

    CONTENTS SECTION 1 – SAFETY ............................1-1 General Warnings............................1-1 Disabling the Vehicle..........................1-2 Disconnecting the Batteries – Electric Vehicles .................... 1-3 Connecting the Batteries – Electric Vehicles ....................1-3 Recycling Lead-Acid Batteries ........................1-3 International safety symbols on batteries ..................... 1-4 SECTION 2 –...
  • Page 6 SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP ................5-1 Pedal Group – Throttle Position Sensor......................5-1 Pedal Group Removal..........................5-1 Throttle Position Sensor (TPS) ........................5-3 Pedal Group Installation ..........................5-3 Pedal Group – MCOR ............................ 5-3 Pedal Group Removal..........................5-3 Pedal Group Installation ..........................
  • Page 7 SECTION 8 – WHEELS AND TIRES ........................8-1 General Information ............................8-1 Wheels ................................. 8-1 Wheel Removal ............................8-1 Wheel Installation ............................8-1 Tires ................................8-2 Tire Removal............................. 8-2 Tire Repair ..............................8-2 Tire Installation ............................8-3 SECTION 9 – REAR SUSPENSION ........................9-1 General Information ............................
  • Page 8 Wiring Diagrams ............................13-3 Troubleshooting............................13-8 Troubleshooting the Vehicle with the IQDM ....................13-8 Troubleshooting Guide 1 .......................... 13-8 Troubleshooting Guide 2 ......................... 13-11 Test Procedures ............................13-13 Battery Warning Light..........................13-35 Communication Display Module (CDM) ......................13-35 Using the CDM to Retrieve Data from the Onboard Computer ..............13-36 CDM Troubleshooting Guide ........................13-38 SECTION 14 –...
  • Page 9 High Speed Walkaway ..........................15-10 Main Coil FAULT.............................15-10 Field Missing ............................15-11 HPD ..............................15-11 Proc/Wiring ............................15-11 Overvoltage............................15-11 Low Battery Voltage ..........................15-11 Thermal Cutback ............................ 15-11 Motor Stall.............................. 15-11 Main Dropout ............................15-11 Open Armature............................15-12 Incorrect Password (IQDM-P only)......................15-12 Max Password Tries (IQDM-P only) ......................15-12 Fault History............................15-12 Clearing Fault History ..........................15-12...
  • Page 10 Fault Count Odometers ..........................16-7 Neg IA 250.............................. 16-7 Neg IA 300.............................. 16-7 Faults Menu ..............................16-8 System Faults ............................16-8 HW Failsafe ............................16-10 Throttle Fault ............................16-10 Speed sensor ............................16-11 Main Welded ............................16-11 Main Driver On ............................16-11 Main Driver Off ............................
  • Page 11 Motor Controller Output Regulator (MCOR) ....................17-8 Testing the MCOR ........................... 17-8 MCOR Removal ............................17-8 MCOR Installation ........................... 17-8 Reverse Buzzer............................17-8 Testing the Reverse Buzzer........................17-8 Reverse Buzzer Removal......................... 17-8 Reverse Buzzer Installation ........................17-9 Electronics Module ............................17-9 Electronics Module Removal ........................
  • Page 12 Fleet Rotation............................18-25 Numbering Vehicles and Chargers......................18-25 Single Point Watering System (SPWS)......................18-25 Initial Maintenance of the SPWS......................18-25 Watering Batteries with the SPWS ......................18-26 Battery Storage ............................18-28 Charging a Battery Pack that has Low Voltage .....................18-28 SECTION 19 – BATTERY CHARGER ......................19-1 SECTION 20 –...
  • Page 13 Vehicle S/N ............................. 23-4 Vehicle Decal ............................23-4 SECTION i – INDEX 2009-2011 Electric Precedent Maintenance and Service Manual Page xi...

  • Page 15: Section 1 - Safety

    SECTION 1 – SAFETY To ensure the safety of those servicing Club Car vehicles, and to protect the vehicles from possible damage resulting from improper service or maintenance, the procedures in this manual must be followed. It is important to note that throughout this manual there are statements labeled DANGER, WARNING, or CAUTION.

  • Page 16: Disabling The Vehicle

    General Warnings SAFETY WARNING • Only trained technicians should service or repair the vehicle or battery charger. Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair. The appropriate instructions must be used when performing maintenance, service, or accessory installation.

  • Page 17: Disconnecting The Batteries - Electric Vehicles

    SAFETY General Warnings DISCONNECTING THE BATTERIES – ELECTRIC VEHICLES Disable the vehicle. See Disabling the Vehicle on page 1-2. Place Tow/Run switch in the TOW position before disconnecting or connecting the batteries. Failure to heed this warning could result in a battery explosion or severe personal injury. Disconnect the batteries, negative (–) cable first, as shown (Figure 1-1) or (Figure 1-2).

  • Page 18: International Safety Symbols On Batteries

    SAFETY must be shared, not only by the manufacturers of the batteries, but by people who use the batteries as well. Please contact your nearest Club Car dealer or distributor for information on how to properly recycle your batteries. 1403...

  • Page 19: Section 2 - Vehicle Specifications

    SECTION 2 – VEHICLE SPECIFICATIONS TWO- FOUR- PASSENGER PASSENGER SPECIFICATIONS ELECTRIC ELECTRIC VEHICLE VEHICLE POWER SOURCE Drive motor: Direct drive, 48 volts DC, shunt-wound, 3.1 hp • • Transaxle: Double reduction helical gear with 12.3:1 direct drive axle • • Electrical system: 48 volts DC, reduced speed reverse •...
  • Page 20 General Warnings VEHICLE SPECIFICATIONS TWO- FOUR- PASSENGER PASSENGER SPECIFICATIONS ELECTRIC ELECTRIC VEHICLE VEHICLE TIRE PRESSURE 18-20 psi (1.24-1.38 18-20 psi (1.24-1.38 Front and rear bars) bars) Page 2-2 2009-2011 Electric Precedent Maintenance and Service Manual...

  • Page 21: Section 3 - General Information

    • See General Warnings on page 1-1. Important features unique to the different models covered in this manual are highlighted. Club Car, LLC recommends the owner/operator read and understand this manual and pay special attention to features specific to their vehicle(s).

  • Page 22: Safety Committee

    • Where golf cars should be driven. • Ensuring that proper warnings of driving hazards are displayed and visible. See below for list of signs available from Club Car Service Parts Department. • Who should and who should not drive golf cars.

  • Page 23: Preparing The Electric Vehicle For Extended Off-Season Storage

    GENERAL INFORMATION Storage CAUTION • Batteries in low state of charge will freeze at low temperatures. • To avoid exposing electrical components to moisture and subsequent damages, do not use any type of pressure washing or steam cleaning equipment to wash the vehicle. •...

  • Page 24: Returning The Stored Electric Vehicle To Service

    Storage GENERAL INFORMATION RETURNING THE STORED ELECTRIC VEHICLE TO SERVICE If necessary, connect batteries. Fully charge batteries. WARNING • Do not attempt to charge frozen batteries or batteries with bulged cases. Discard the battery. Frozen batteries can explode. Adjust tire to recommended pressure. See Section 2 – Vehicle Specifications. Perform the Pre-Operation and Daily Safety Checklist.

  • Page 25: Section 4 - Body And Trim

    A garden hose at normal residential water pressure is adequate. Club Car does not recommend any type of pressure washing or steam cleaning. Such a process (especially if the vehicle has a Surlyn rear body that is removed) will expose electrical components to moisture. Moisture entering electrical components can result in water damage and subsequent component failure.

  • Page 26: Front And Rear Body Repair

    Front and Rear Body Repair BODY AND TRIM Difficult Stains: Dampen a soft, white cloth with a solution of 10% household bleach (sodium hypochlorite) and 90% water. Rub gently to remove stain, then rinse with a water dampened cloth to remove bleach concentration. More Difficult Stains: Perform previous procedure using full-strength bleach, or allow bleach to puddle on affected area for approximately 30 minutes.

  • Page 27: Minor Scratches And Surface Blemishes

    BODY AND TRIM Front Body MINOR SCRATCHES AND SURFACE BLEMISHES For minor scratches or blemishes in the Surlyn body that do not penetrate the finish: Thoroughly clean the affected area using a strong, non-abrasive detergent and hot water, then clean with Ultra-Kleen ®...
  • Page 28 Front Body BODY AND TRIM Figure 4-1 Front Body Page 4-4 2009-2011 Electric Precedent Maintenance and Service Manual...

  • Page 29: Front Bumper

    BODY AND TRIM Front Bumper FRONT BUMPER The underbody bracket (1) connects the front suspension to the front underbody (Figure 4-2, Page 4-5). Each bracket is secured in place by two taptite screws (2) tightened to 13 ft-lb (17.6 N·m). The front bumper (3) is attached to the vehicle frame rails by nuts (5) and bolts (4).

  • Page 30: Instrument Panel

    Instrument Panel BODY AND TRIM INSTRUMENT PANEL See General Warnings on page 1-1. INSTRUMENT PANEL REMOVAL Remove two screws (1) at sides and one screw (2) on top of instrument panel (3) (Figure 4-3, Page 4-6). Tilt instrument panel up to release it from the dash assembly (4). Disconnect the electrical connector on the passenger side of the instrument panel (3) and remove the panel.

  • Page 31: Floor Mat And Retainers

    BODY AND TRIM Floor Mat and Retainers FLOOR MAT AND RETAINERS See General Warnings on page 1-1. The floor mat retainers secure the floor mat to the vehicle and also provide a clean appearance to the side of the vehicle. Normally, if only the floor mat (3) needs to be removed, the screws (2) must be removed to allow the floor mat to be slid from beneath the retainers (1) (Figure 4-4, Page 4-7).

  • Page 32: Kick Plate And Charger Receptacle Bezel

    Kick Plate and Charger Receptacle Bezel BODY AND TRIM KICK PLATE AND CHARGER RECEPTACLE BEZEL See General Warnings on page 1-1. KICK PLATE AND CHARGER RECEPTACLE BEZEL REMOVAL If charger bezel (4) requires removal, use charger bezel tool (P/N 102562401) to remove bezel from the kick plate (Figure 4-5, Page 4-8).

  • Page 33: Rear Body - Two-Passenger Vehicles

    BODY AND TRIM Rear Body – Two-Passenger Vehicles REAR BODY – TWO-PASSENGER VEHICLES See General Warnings on page 1-1. UNIVERSAL ACCESSORY MOUNTING The Structural Accessory Module (SAM) includes two threaded inserts on both the driver side and the passenger side (Figure 4-6, Page 4-9).
  • Page 34 Rear Body – Two-Passenger Vehicles BODY AND TRIM Figure 4-7 Backrest and SAM Page 4-10 2009-2011 Electric Precedent Maintenance and Service Manual...

  • Page 35: Rear Body Components (Two-Passenger)

    BODY AND TRIM Rear Body – Two-Passenger Vehicles REAR BODY COMPONENTS (TWO-PASSENGER) Rear Beauty Panel Removal Remove SAM. See SAM Removal on page 4-9. Remove one screw (3) from each canopy support bracket (1 and 2) (Figure 4-8, Page 4-12). Remove canopy supports.
  • Page 36 Rear Body – Two-Passenger Vehicles BODY AND TRIM * Two-Passenger Vehicles Only Figure 4-8 Rear Body Components Page 4-12 2009-2011 Electric Precedent Maintenance and Service Manual...

  • Page 37: Rear Body - Four-Passenger Vehicles

    BODY AND TRIM Rear Body – Four-Passenger Vehicles REAR BODY – FOUR-PASSENGER VEHICLES See General Warnings on page 1-1. SEAT BACKS Seat Back Removal Remove screws (9 or 13) securing seat back (8 or 11) to seat support and remove the seat back (Figure 4-9, Page 4-13).

  • Page 38: Foot Deck

    Rear Body – Four-Passenger Vehicles BODY AND TRIM Seat Support Installation Install in the reverse order of removal. Tighten bolts (4) to 53 in-lb (6 N·m). Tighten screws (5) to 44 in-lb (5 N·m). Tighten bolts (8 and 11) to 124 in-lb (14 N·m) (Figure 4-10, Page 4-14).

  • Page 39: Rear Body Components (Four-Passenger)

    BODY AND TRIM Rear Body – Four-Passenger Vehicles Figure 4-11 Foot Deck (Four-Passenger Vehicles) REAR BODY COMPONENTS (FOUR-PASSENGER) Rear Beauty Panel Removal Remove seat support. See Seat Support Removal on page 4-13. Remove four screws (13) attaching the rear beauty panel (12) to the fuel bucket (Figure 4-8, Page 4-12). Remove two screws (14) and remove the Forward/Reverse switch housing (15) from vehicle.

  • Page 40: Canopy - Two-Passenger

    Canopy – Two-Passenger BODY AND TRIM Lift the rear edge of the rear underbody (4) until the front portion slides out from beneath the front underbody. Remove the rear underbody from the vehicle. Rear Underbody Installation Install rear underbody (4) on the vehicle (Figure 4-8, Page 4-12). Install four screws (5) to secure the underbody to its vehicle.
  • Page 41 BODY AND TRIM Canopy – Two-Passenger 2378 Figure 4-12 Precedent Two-Passenger Canopy 2009-2011 Electric Precedent Maintenance and Service Manual Page 4-17...

  • Page 42: Two-Passenger Canopy Installation

    Canopy – Four-Passenger BODY AND TRIM TWO-PASSENGER CANOPY INSTALLATION Install the front canopy supports. 1.1. Ensure the front supports are properly oriented to the correct side of the vehicle as shown (Figure 4-12, Page 4-17). The lower profile of each support follows the profile of the vehicle. If the supports are placed on the wrong side of the vehicle, they will not follow the vehicle’s profile.

  • Page 43: Four-Passenger Canopy Installation

    BODY AND TRIM Canopy – Four-Passenger Remove the nuts (14) and bolts (13) from the canopy (9) and the rear support (6). Lift canopy (9) away from front canopy supports (1) and rear support (6). Remove screws (5) securing front canopy support covers to front body. Slide canopy support covers (4) up front canopy supports (1) to gain access to bolts (2).
  • Page 44 Canopy – Four-Passenger BODY AND TRIM Figure 4-13 Precedent Four-Passenger Canopy Page 4-20 2009-2011 Electric Precedent Maintenance and Service Manual...

  • Page 45: Canopy (Monsoon Version) - Four-Passenger

    BODY AND TRIM Canopy (Monsoon Version) – Four-Passenger CANOPY (MONSOON VERSION) – FOUR-PASSENGER See General Warnings on page 1-1. CAUTION • To prevent damage to the canopy, do not remove the canopy supports (1, 2, 8 and 9) from the vehicle without first removing the canopy (13) (Figure 4-16, Page 4-24).
  • Page 46 Canopy (Monsoon Version) – Four-Passenger BODY AND TRIM K-00538.eps Figure 4-14 Secure Rear Supports to Seat Support Bracket Attach the front canopy supports. 2.1. Ensure the front supports are properly oriented to the correct side of the vehicle as shown (Figure 4-15). The lower profile of each support follows the profile of the vehicle.
  • Page 47 BODY AND TRIM Canopy (Monsoon Version) – Four-Passenger K-00504.eps Figure 4-15 Properly Orient the Front Supports With the aid of an assistant, position the canopy (13) to the top of the front supports (8 and 9) and rear supports (1 and 2). Secure the front canopy brackets (under the canopy) (14) to the front supports (8 and 9) with four 1/4-20 x 1-1/2 hex head bolts (15), eight 1/4-inch flat washers (16) and four 1/4-20 nylon lock nuts (17).
  • Page 48 Canopy (Monsoon Version) – Four-Passenger BODY AND TRIM K-00537.eps Figure 4-16 Secure Canopy Page 4-24 2009-2011 Electric Precedent Maintenance and Service Manual...

  • Page 49: Section 5 - Accelerator And Brake Pedal Group

    SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. PEDAL GROUP – THROTTLE POSITION SENSOR See General Warnings on page 1-1. PEDAL GROUP REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-3.
  • Page 50 Pedal Group – Throttle Position Sensor ACCELERATOR AND BRAKE PEDAL GROUP 1307 Figure 5-2 Pedal Group (with TPS) Remove two screws (2) on the driver side of the pedal group and two screws (1) on the passenger side of the pedal group. Disconnect six-pin connector (12) from throttle position sensor.

  • Page 51: Throttle Position Sensor (Tps)

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group – MCOR THROTTLE POSITION SENSOR (TPS) The pedal group for the Precedent electric vehicle includes a throttle position sensor mounted on the side of the accelerator pedal assembly. The throttle position sensor detects the position of the accelerator pedal and sends a corresponding voltage to the motor controller.

  • Page 52: Pedal Group Installation

    Pedal Group – MCOR ACCELERATOR AND BRAKE PEDAL GROUP Figure 5-3 Pedal Group Access Remove fastener (10) and lift off cover plate (7) (Figure 5-4, Page 5-5). Loosen jam nuts (4 and 5) on each side of turnbuckle (6). NOTE: Nut (4) has a left-hand thread. Loosen turnbuckle (6) until the threaded rod (8) from the pedal group (11) is free of the turnbuckle (Figure 5-4, Page 5-5).

  • Page 53: Debris Shields

    ACCELERATOR AND BRAKE PEDAL GROUP Debris Shields 2375 Figure 5-4 Pedal Group (with MCOR) DEBRIS SHIELDS Debris shields on the top face of the pedal group prevent excessive debris from contacting the moving parts of the pedal group. Both shields (4 and 5) are held in place by tabs that snap into the pedal group mounting plate (Figure 5-5, Page 5-7).

  • Page 54: Accelerator Pedal Removal

    Accelerator Pedal Removal ACCELERATOR AND BRAKE PEDAL GROUP ACCELERATOR PEDAL REMOVAL Remove pedal group from vehicle. See Pedal Group Removal on page 5-1. Vehicles with an MCOR: Remove the MCOR. See MCOR Removal on page 17-8. Remove debris shields (4 and 5) (Figure 5-5, Page 5-7). Remove four screws (13) securing accelerator pedal assembly (9) to pedal group mounting plate and pull accelerator pedal assembly through bottom of pedal group mounting plate.
  • Page 55 ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal Installation 000487-002 Figure 5-5 Accelerator Pedal Assembly and Brake Pedal Assembly 2009-2011 Electric Precedent Maintenance and Service Manual Page 5-7...

  • Page 57: Section 6 - Wheel Brake Assemblies

    SECTION 6 – WHEEL BRAKE ASSEMBLIES DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. Asbestos Dust Warning • Some aftermarket brake shoes contain asbestos fiber, and asbestos dust is created when these brake mechanisms are handled.
  • Page 58 Brake Shoe Removal WHEEL BRAKE ASSEMBLIES 7.1. On the back of each brake cluster assembly, locate the heads of two brake shoe retainer pins. It may be necessary to remove sealant material around the head of each pin. 1400-18100-10220 Figure 6-1 Loosen Turnbuckle Figure 6-2 Shoe Retainer Pins 7.2.
  • Page 59 WHEEL BRAKE ASSEMBLIES Brake Shoe Removal Figure 6-4 Self-adjusting Wheel Brake Assembly Using needle nose pliers, turn the clip retainer pin (1) 90° to remove the shoe retainer clip (2) (Figure 6-5, Page 6-4). CAUTION • The brake shoes are under pressure and can release suddenly when brake shoe retainers are removed. 10.
  • Page 60 Brake Shoe Removal WHEEL BRAKE ASSEMBLIES 1400-18100-10222 1400-17700-10225 Figure 6-5 Remove Shoe Retainer Clip Figure 6-6 Remove Brake Shoes 1. Slide 2. Slide Plate (If Equipped) Figure 6-7 Remove Adjuster Wheel Figure 6-8 Lubricate Slide Page 6-4 2009-2011 Electric Precedent Maintenance and Service Manual...

  • Page 61: Brake Assembly Cleaning

    WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning BRAKE ASSEMBLY CLEANING See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. NOTE: Later model vehicles are no longer equipped with the slide plate. Carefully clean the brake backing plate and all of its mechanical components. Remove the rubber boot from backing plate and wipe with a clean damp cloth.
  • Page 62 Brake Assembly Cleaning WHEEL BRAKE ASSEMBLIES Figure 6-11 Apply Grease To Brake Adjuster Figure 6-12 Install Adjuster Wheel, Trailing Shoe Page 6-6 2009-2011 Electric Precedent Maintenance and Service Manual...

  • Page 63: Brake Shoe Installation

    WHEEL BRAKE ASSEMBLIES Brake Shoe Installation BRAKE SHOE INSTALLATION See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. Turn the adjusting wheel screw so that the shoe slot is vertical, then position the trailing shoe in the slots in the shoe mounting block and adjuster assembly (Figure 6-12, Page 6-6).
  • Page 64 Brake Shoe Installation WHEEL BRAKE ASSEMBLIES Figure 6-15 Install Leading Shoe Figure 6-16 Check Shoe Positions Place a flatblade screwdriver under the adjusting arm (1) and raise the arm off of the adjusting wheel (2). While holding the arm (1) up, turn the wheel (2) upward until it stops (Figure 6-17, Page 6-8). Remove the screwdriver. Figure 6-17 Set Adjusting Wheel Install the rear axle onto the transaxle.
  • Page 65 WHEEL BRAKE ASSEMBLIES Brake Shoe Installation WARNING • Be sure retaining ring is properly seated in groove. If ring is not properly installed, the axle assembly will separate from the transaxle and damage the axle assembly and other components. Loss of vehicle control could result in severe personal injury or death.

  • Page 66: Brake Cable Equalizer Adjustment

    Brake Cable Equalizer Adjustment WHEEL BRAKE ASSEMBLIES BRAKE CABLE EQUALIZER ADJUSTMENT See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. After maintenance on the brake system is complete, lower the vehicle onto the floor. With the brake pedal in the full up or at rest position, adjust the turnbuckle (1) until the proper brake tension is achieved (Figure 6-18, Page 6-9).

  • Page 67: Brake Cluster Removal And Installation

    WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation BRAKE CLUSTER REMOVAL AND INSTALLATION See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. BRAKE CLUSTER REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-3.
  • Page 68 Brake Cluster Removal and Installation WHEEL BRAKE ASSEMBLIES NOTE: There is a LEFT and RIGHT side axle. The splined portions on the axles that insert into the transaxle case are two different lengths. The longest length spline is the LEFT, or driver side axle. 4.1.

  • Page 69: Brake Cable Removal And Installation

    WHEEL BRAKE ASSEMBLIES Brake Cable Removal and Installation BRAKE CABLE REMOVAL AND INSTALLATION See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. NOTE: Beginning with Precedent vehicle serial number PD0918-020874, a new brake cable design (Figure 6-19, Page 6-13) and equalizer bracket design are used.

  • Page 70: Brake Cable Installation

    Brake Cable Removal and Installation WHEEL BRAKE ASSEMBLIES Figure 6-20 Loosen Brake Cables Rotate the bolt (5) and equalizer bracket (4) to the upright position then slip the cable heads out of the bracket. Remove nut (1) from the bolt (2) that secures front of the leaf spring (Figure 6-22, Page 6-14). Do not remove bolt (2).
  • Page 71 WHEEL BRAKE ASSEMBLIES Brake Cable Removal and Installation NOTE: The driver-side and passenger-side brake cables are not interchangeable. The driver-side cable is shorter than the passenger-side cable. Make sure the correct cable is used on the correct side. Be sure to orient the cable so that the clevis end goes to the wheel rather than to the equalizer bracket. Insert the end of the new brake cable through the hole in the frame (Figure 6-20, Page 6-14).

  • Page 73: Section 7 - Steering And Front Suspension

    SECTION 7 – STEERING AND FRONT SUSPENSION DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION Steering is controlled through a rack and pinion steering assembly that is connected by a steering column to a steering wheel.

  • Page 74: Steering Wheel Installation

    Steering Column STEERING AND FRONT SUSPENSION Figure 7-1 Steering Wheel Removal Figure 7-2 Steering Wheel Puller STEERING WHEEL INSTALLATION NOTE: To minimize corrosion and to make future removal of the steering wheel easier, apply a small amount of oil or anti-seize compound to steering shaft before installing the steering wheel.

  • Page 75: Steering Column Installation

    STEERING AND FRONT SUSPENSION Steering Column Figure 7-3 Steering Column STEERING COLUMN INSTALLATION For ease of assembly and to prevent corrosion, apply a light coat of anti-seize or lubricating compound to the splined stud extending from the steering gear. 2009-2011 Electric Precedent Maintenance and Service Manual Page 7-3...

  • Page 76: Rack And Pinion

    Rack and Pinion STEERING AND FRONT SUSPENSION Insert the end of the steering column with the universal joint through the front underbody. Install universal joint onto pinion shaft of steering gear. Loosely install bolt (11). Do not tighten until steering column is mounted to frame in step 3 (Figure 7-3, Page 7-3).

  • Page 77: Rack And Pinion Removal

    STEERING AND FRONT SUSPENSION Rack and Pinion 1383 Figure 7-4 Rack and Pinion Removal RACK AND PINION REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-3. Remove the front bumper as instructed. See Section 4 – Body and Trim. Remove the tie rod end retaining nuts (2) (Figure 7-4, Page 7-5).
  • Page 78 Rack and Pinion STEERING AND FRONT SUSPENSION Remove rack screw nut (14), rack guide screw (13), rack guide pressure spring (15) and the rack guide (16). Remove bolt (6) and slide universal joint off the pinion shaft (Figure 7-4, Page 7-5). Remove the dust seal (Figure 7-6, Page 7-8).
  • Page 79 STEERING AND FRONT SUSPENSION Rack and Pinion 1384 Figure 7-5 Steering Gear 2009-2011 Electric Precedent Maintenance and Service Manual Page 7-7...

  • Page 80: Rack And Pinion Assembly

    Rack and Pinion STEERING AND FRONT SUSPENSION Figure 7-6 Remove Dust Seal Figure 7-7 Pinion Snap Rings 1. Press Ram 2. Pinion Gear 3. Bearing Figure 7-8 Remove Pinion from Housing Figure 7-9 Remove Bearing from Pinion RACK AND PINION ASSEMBLY Apply a liberal amount of EP grease to the teeth of the rack (18), then slide the rack through the bushing (7) and housing (17) (Figure 7-5, Page 7-7).

  • Page 81: Rack And Pinion Installation

    STEERING AND FRONT SUSPENSION Rack and Pinion CAUTION • Do not force the pinion-bearing assembly into the housing. The gear teeth or the small bearing could be damaged. Install the large snap ring (2). Use a socket (1) to apply pressure evenly and press in a new dust seal (2) (Figure 7-10, Page 7-10). Apply a small amount of grease to the rack guide (16) where it comes into contact with the rack (18) (Figure 7-5, Page 7-7).
  • Page 82 Rack and Pinion STEERING AND FRONT SUSPENSION Test drive vehicle before returning it to service. Figure 7-10 Press In Dust Seal Figure 7-11 Install Ball Joint Figure 7-12 Rack and Pinion Adjustment Figure 7-13 Rack and Pinion Resistance Page 7-10 2009-2011 Electric Precedent Maintenance and Service Manual...

  • Page 83: Front Suspension

    STEERING AND FRONT SUSPENSION Front Suspension FRONT SUSPENSION See General Warnings on page 1-1. LUBRICATION Two grease fittings are provided (one in each spindle housing). Lubricate these fittings at the recommended interval with the proper lubricant. See Periodic Lubrication Schedule on page 10-6. CAUTION •...
  • Page 84 Front Suspension STEERING AND FRONT SUSPENSION Figure 7-14 Check Camber Figure 7-15 Adjust Camber Toe-in Adjustment On a level surface, roll the vehicle forward, then stop. Make sure the front wheels are pointed straight ahead. Do not turn the steering wheel again during this procedure. On each front tire, mark (as closely as possible) the center of the tread face that is oriented toward the rear of the vehicle.

  • Page 85: Front Suspension Components

    STEERING AND FRONT SUSPENSION Front Suspension Components 6.2. Rotate both of the drag links equally. To increase the toe-in, rotate both drag links counterclockwise. To decrease the toe-in, rotate both drag links clockwise. Maintain an equal distance from the ball joint to the end of the threads on each drag link (Figure 7-18, Page 7-13).

  • Page 86: Leaf Spring Removal

    Front Suspension Components STEERING AND FRONT SUSPENSION LEAF SPRING REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-3. Loosen lug nuts on both front wheels and raise front of vehicle with a chain hoist or floor jack. Place jack stands under the aluminum rails of the vehicle frame just aft of the front suspension.

  • Page 87: Control Arm Removal

    STEERING AND FRONT SUSPENSION Front Suspension Components Install the wave washer (6) on the kingpin. Install the steering spindle on the kingpin. Place upper clevis over the kingpin threads and install nut (1). Tighten the nut to 70 ft-lb (95 N·m). Attach the tie rod ends (12) to the spindle tabs, then install and tighten the nuts (14) to 70 ft-lb (95 N·m) (Figure 7-19, Page 7-16).
  • Page 88 Front Suspension Components STEERING AND FRONT SUSPENSION 1311 Figure 7-19 Upper Front Suspension Assembly Page 7-16 2009-2011 Electric Precedent Maintenance and Service Manual...
  • Page 89 STEERING AND FRONT SUSPENSION Front Suspension Components 1312 Figure 7-20 Lower Front Suspension Assembly 2009-2011 Electric Precedent Maintenance and Service Manual Page 7-17...

  • Page 90: Front Wheel Bearings And Hubs

    Front Wheel Bearings and Hubs STEERING AND FRONT SUSPENSION FRONT WHEEL BEARINGS AND HUBS See General Warnings on page 1-1. NOTE: The front wheel bearings are pressed into the spindle and are not serviceable. If excessive free-play is detected the entire hub should be replaced. FRONT WHEEL FREE PLAY INSPECTION Disconnect the batteries and discharge the controller.
  • Page 91 STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs Figure 7-21 Front Wheel Hub 2009-2011 Electric Precedent Maintenance and Service Manual Page 7-19...

  • Page 93: Section 8 - Wheels And Tires

    SECTION 8 – WHEELS AND TIRES DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION Maximum tire life and good vehicle handling qualities are directly related to proper wheel and tire care. •...

  • Page 94: Tires

    Tires WHEELS AND TIRES TIRES See General Warnings on page 1-1. TIRE REMOVAL NOTE: Tire must be removed or installed from the valve stem side of the rim. Remove the tire and wheel assembly from the vehicle as instructed above. Remove the valve cap and valve core and allow air to escape from the tire.

  • Page 95: Tire Installation

    Small holes in the casing can be plugged using a standard automotive tubeless tire repair kit available at your local Club Car dealer. When the cause of the air leak has been determined, remove tire from the rim and repair as required. See Tire Removal on page 8-2.
  • Page 96 Tires WHEELS AND TIRES Figure 8-2 Inflate Tire Page 8-4 2009-2011 Electric Precedent Maintenance and Service Manual...

  • Page 97: Section 9 - Rear Suspension

    SECTION 9 – REAR SUSPENSION DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION The rear suspension and powertrain of the vehicle move independently from the vehicle frame. It consists of two leaf springs controlled by two shock absorbers mounted between the springs and the vehicle frame.

  • Page 98: Leaf Springs (Two-Passenger Vehicles)

    Leaf Springs (Two-Passenger Vehicles) REAR SUSPENSION LEAF SPRINGS (TWO-PASSENGER VEHICLES) See General Warnings on page 1-1. LEAF SPRING REMOVAL (TWO-PASSENGER VEHICLES) Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-3. Loosen, but do not remove, lug nuts on tire and wheel assembly on the side from which the spring is to be removed.

  • Page 99: Leaf Spring Installation (Two-Passenger Vehicles)

    REAR SUSPENSION Leaf Springs (Two-Passenger Vehicles) Figure 9-1 Support Vehicle on Jack Stands Figure 9-2 Disconnect Brake Cable LEAF SPRING INSTALLATION (TWO-PASSENGER VEHICLES) To install the springs, reverse the removal procedure. See following CAUTION. CAUTION • When positioning the spring on the transaxle, be sure to insert the locating bolt on the spring in the locating hole in the transaxle saddle.

  • Page 100: Leaf Springs (Four-Passenger Vehicles)

    Leaf Springs (Four-Passenger Vehicles) REAR SUSPENSION Figure 9-3 Rear Suspension Assembly and Mounting (Two-Passenger Vehicles) LEAF SPRINGS (FOUR-PASSENGER VEHICLES) See General Warnings on page 1-1. LEAF SPRING REMOVAL (FOUR-PASSENGER VEHICLES) Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-3.

  • Page 101: Leaf Spring Installation (Four-Passenger Vehicles)

    REAR SUSPENSION Leaf Springs (Four-Passenger Vehicles) Loosen, but do not remove, lug nuts on tire and wheel assembly on the side from which the spring is to be removed. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands under the frame crossmember forward of the spring mounting tabs.
  • Page 102 Leaf Springs (Four-Passenger Vehicles) REAR SUSPENSION Figure 9-4 Rear Suspension Assembly and Mounting (Four-Passenger Vehicles) Page 9-6 2009-2011 Electric Precedent Maintenance and Service Manual...

  • Page 103: Section 10 - Periodic Maintenance

    SECTION 10 – PERIODIC MAINTENANCE GENERAL WARNING The following safety statements must be heeded whenever the vehicle is being operated, repaired, or serviced. Service technicians should become familiar with these general safety statements, which can be found throughout this manual. Also, other specific safety statements appear throughout this manual and on the vehicle.
  • Page 104 General Warning PERIODIC MAINTENANCE WARNING • Use insulated tools when working near batteries or electrical connections. Use extreme caution to avoid shorting of components or wiring. • Turn key switch OFF and remove key, place Forward/Reverse switch in the NEUTRAL position, and chock the wheels prior to servicing the vehicle.

  • Page 105: General Information

    Any vehicle not functioning correctly should be removed from use until it is properly repaired. This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service. PERIODIC SERVICE SCHEDULE WARNING •...
  • Page 106 Periodic Service Schedule PERIODIC MAINTENANCE PERIODIC SERVICE SCHEDULE – ELECTRIC VEHICLES REGULAR INTERVAL SERVICE See Pre-Operation and Daily Safety Checklist Pre-Operation and Daily Safety Checklist in the appropriate Owner’s Manual Daily service by owner See Performance Inspection in the appropriate Performance Inspection Owner’s Manual Batteries...
  • Page 107 PERIODIC MAINTENANCE Periodic Service Schedule PERIODIC SERVICE SCHEDULE – ELECTRIC VEHICLES REGULAR INTERVAL SERVICE If batteries are not performing as expected, Batteries see Batteries on page 18-1. Annual service by trained technician only (every 100 hours of operation or 200 rounds Lubricate all rotating joints.

  • Page 108: Periodic Lubrication Schedule

    Periodic Lubrication Schedule PERIODIC MAINTENANCE PERIODIC LUBRICATION SCHEDULE See General Warnings, Section 1, Page 1-1. PERIODIC LUBRICATION SCHEDULE LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINT Charger receptacle WD-40 Semiannually by owner or trained technician (every 50 Brake system, per maintenance and Dry Moly Lube (P/N 1012151), white lithium hours of operation or 100 rounds service manual.

  • Page 109: Section 11 - Iq System Troubleshooting - Tps

    SECTION 11 – IQ SYSTEM TROUBLESHOOTING – TPS DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. • Shorting of battery terminals can cause personal injury or death. – Do not place component mounting plate directly on top of batteries when removing or installing plate.

  • Page 110: Wiring Diagrams

    Wiring Diagrams IQ SYSTEM TROUBLESHOOTING – TPS WIRING DIAGRAMS #16 BLK/WHT #18 BLK #12 BLUE LEFT 10-AMP FUSE SO NIC #16 BROWN #18 BRN TAILLIGHT WELD #18 RED #16 WHITE #16 BLACK/WHITE #16 BLK/WHT #18 BLK CONNECTS T O #16 BROWN RIGHT #16 BROWN #18 BRN...
  • Page 111 IQ SYSTEM TROUBLESHOOTING – TPS Wiring Diagrams WD1034969-5-R Figure 11-2 Wiring Diagram – IQ System with TPS (Continued) 2009-2011 Electric Precedent Maintenance and Service Manual Page 11-3...
  • Page 112 Wiring Diagrams IQ SYSTEM TROUBLESHOOTING – TPS USED WHEN THERE ARE LIGHTS BUT NO TURN S IGNAL. NORMALLY OPEN MOM ENTARY PUSH BU TTON FOR HORN 9-PIN #16 ORANGE CONNECT OR #16 BLUE/WHITE #16 WHITE #16 YELLOW SONIC #16 BROWN/WHITE WELD FLASHER UNIT...
  • Page 113 IQ SYSTEM TROUBLESHOOTING – TPS Wiring Diagrams HEADLIGHT ASSEMBLY DC - DC HORN CONVERTER SONIC 20 AMP WELD #16 BLACK FUS E SONIC WELD #18 O RANGE DIODE #16 BLACK/WHITE #12 BLACK SON IC WELD #16 BLACK SON IC WELD CONNE CTS TO MAIN HARNESS.
  • Page 114 Wiring Diagrams IQ SYSTEM TROUBLESHOOTING – TPS KEY SWITCH OP TIONAL BATTERY INDICATOR 9-PIN CONNECTOR. SONIC WELD CONNECTS TO MAIN HARNESS. SEE FIGURES 11-1 AND 11-2. #18 RED #16 BLUE #16 GREEN/RED #18 BLACK/YELLOW #18 BROWN/WHITE #18 BROWN/WHITE #18 ORANGE/WHITE #18 RED #18 YELLOW #18 GREEN...

  • Page 115: Troubleshooting

    (17.7 km/h), with the accelerator pedal still released, motor braking will be deactivated and the vehicle will coast freely. This feature is selectable. Contact your Club Car dealer/distributor to inquire about this selectable feature. • Regenerative Braking: When motor braking is activated, the vehicle motor acts as a generator, slowing the vehicle as it creates energy that is used to charge the batteries.

  • Page 116: Troubleshooting Guide 1

    Future IQ system controllers will have software to prevent this as well. Club Car recommends the use of the IQDM handset for troubleshooting vehicles equipped with the IQ electrical system. Troubleshooting Guide 1 is to be used in conjunction with the IQDM handset. See IQ Display Module (IQDM) and IQDM-P Diagnostics: IQ System on page 15-1 for operating instructions.
  • Page 117 IQ SYSTEM TROUBLESHOOTING – TPS Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected six-pin connector at the Repair and/or connect the six-pin connector to throttle position sensor or broken wire the throttle position sensor Test Menu – FOOT INPUT menu item indicates Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector that the throttle position sensor internal limit...
  • Page 118 Troubleshooting IQ SYSTEM TROUBLESHOOTING – TPS TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Armature drive FET’s (field-effect transistors) Replace the speed controller. See Speed inside speed controller have failed Controller Removal on page 17-12. Disconnect the batteries and allow the Diagnostic Menu –...

  • Page 119: Troubleshooting Guide 2

    IQ SYSTEM TROUBLESHOOTING – TPS Troubleshooting TROUBLESHOOTING GUIDE 2 TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Batteries – Batteries discharged Charge batteries Check vehicle wiring. See Wiring Diagrams Batteries – Battery connections on page 11-2. Battery charger is connected to the vehicle Disconnect the battery charger from the –...
  • Page 120 Troubleshooting IQ SYSTEM TROUBLESHOOTING – TPS TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Test Procedure 21 – Motor Speed Sensor on Speed sensor disconnected or failed page 11-31 To change the programmed top speed of the Incorrect speed setting vehicle, an IQDM-P handset must be used Check vehicle wiring.

  • Page 121: Test Procedures

    IQ SYSTEM TROUBLESHOOTING – TPS Test Procedures TEST PROCEDURES Using the following procedures, the entire IQ electrical system can be tested without major disassembly of the vehicle. WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.
  • Page 122 Test Procedures IQ SYSTEM TROUBLESHOOTING – TPS 21 – Motor Speed Sensor 22 – Solenoid Continuity 23 – Forward/Reverse Rocker Switch 24 – Reverse Buzzer 25 – Rebooting the Onboard Computer 26 – Battery Warning Light TEST PROCEDURE 1 – Batteries / Voltage Check See General Warnings on page 1-1.
  • Page 123 IQ SYSTEM TROUBLESHOOTING – TPS Test Procedures TEST PROCEDURE 2 – Onboard Computer Solenoid Lockout Circuit See General Warnings on page 1-1. The solenoid lockout circuit disables the vehicle when the battery charger is plugged into the vehicle. Use the following procedure to test the solenoid lockout circuit: With batteries connected, place the Tow/Run switch in the RUN position.
  • Page 124 Test Procedures IQ SYSTEM TROUBLESHOOTING – TPS – A reading of 200 to 250 ohms should be obtained for factory-installed solenoids (Figure 11-8, Page 11-16). If not, replace the solenoid. – A reading of 180 to 190 ohms should be obtained for service replacement solenoids (Figure 11-9, Page 11-16).
  • Page 125 IQ SYSTEM TROUBLESHOOTING – TPS Test Procedures on the black/white wire at a point close to the six-pin connector at the throttle position sensor. The reading should be approximately 48-50 volts (full battery voltage). If reading is zero volts, check the black/white wire continuity from the six-pin connector at the throttle position sensor to the 16-pin connector at the speed controller.
  • Page 126 Test Procedures IQ SYSTEM TROUBLESHOOTING – TPS 4.2. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-3. 4.3. Check continuity on A1 and A2 motor terminal posts and continuity of the F1 and F2 motor terminal posts. Also, check continuity of all motor wires.
  • Page 127 IQ SYSTEM TROUBLESHOOTING – TPS Test Procedures (Viewed from driver side of vehicle) (Viewed from driver side of vehicle) 1. RED probe to battery no. 1 (+). 1. RED probe to battery no. 1 (+). 2. BLACK probe to battery no. 4 (-). 2.
  • Page 128 Test Procedures IQ SYSTEM TROUBLESHOOTING – TPS TEST PROCEDURE 8 – Key Switch and Throttle Position Sensor Limit Switch Circuit See General Warnings on page 1-1. Key Switch and Throttle Position Sensor Limit Switch Circuit Test with the IQDM Handset Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack.
  • Page 129 IQ SYSTEM TROUBLESHOOTING – TPS Test Procedures 4.5. If any other reading is obtained, replace the key switch. See Key Switch Removal on page 17-1. 4.6. If the key switch operates as described in the previous steps, install the instrument panel in the reverse order of removal and proceed to the following step.
  • Page 130 Test Procedures IQ SYSTEM TROUBLESHOOTING – TPS If the results of any of the referenced procedures are different from those described in the procedure, check the continuity of the wires in the wire harness and test the connected components with the appropriate test procedures. See Index of Test Procedures.
  • Page 131 IQ SYSTEM TROUBLESHOOTING – TPS Test Procedures Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands under the frame rails just forward of each spring mount. See WARNING “Lift only one end...” in General Warnings on page 1-1.
  • Page 132 Test Procedures IQ SYSTEM TROUBLESHOOTING – TPS TEST PROCEDURE 12 – Pin 6 See General Warnings on page 1-1. Pin 6 in the 16-pin connector provides a connection point for the throttle position sensor limit switch to the speed controller. A 48 volt signal is sent through this wire when the accelerator pedal is pressed, completing the circuit inside the throttle position sensor.
  • Page 133 IQ SYSTEM TROUBLESHOOTING – TPS Test Procedures Figure 11-13 Pin 7 Test TEST PROCEDURE 14 – Pins 8 and 16 See General Warnings on page 1-1. Pins 8 and 16 in the 16-pin connector provide a connection point for the Forward/Reverse rocker switch to the speed controller.
  • Page 134 Test Procedures IQ SYSTEM TROUBLESHOOTING – TPS 12. Place the Forward/Reverse switch in the REVERSE position. The multimeter should indicate full battery voltage (approximately 48 volts). 13. If any other reading is obtained, check the following items: – Continuity of the wires in the wire harness –...
  • Page 135 IQ SYSTEM TROUBLESHOOTING – TPS Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with Tow/Run switch in RUN position) Figure 11-15 Pin 9 Test With the Tow/Run switch in the RUN position, the multimeter should indicate full battery voltage (approximately 48 volts).
  • Page 136 Test Procedures IQ SYSTEM TROUBLESHOOTING – TPS WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with Tow/Run switch in RUN and key switch in the ON position) Figure 11-16 Pin 10 Test With the key switch in the ON position, the multimeter should indicate full battery voltage (approximately 48 volts). With the key switch in the OFF position, the reading should be zero volts.
  • Page 137 IQ SYSTEM TROUBLESHOOTING – TPS Test Procedures Figure 11-17 Pin 12 Test The solenoid should click when the key switch is placed in the ON position. If any other activity is observed, check the following items: – Continuity of the wires in the wire harness –...
  • Page 138 Test Procedures IQ SYSTEM TROUBLESHOOTING – TPS TEST PROCEDURE 19 – Onboard Computer Gray Wire See General Warnings on page 1-1. With batteries connected and the DC cord disconnected, pull back on the boot (1) on the gray wire (2) connection at the OBC (3) (Figure 11-18, Page 11-30).
  • Page 139 IQ SYSTEM TROUBLESHOOTING – TPS Test Procedures TEST PROCEDURE 21 – Motor Speed Sensor See General Warnings on page 1-1. Motor Speed Sensor Test with the IQDM Handset CAUTION • Perform the following procedure only on a level surface. To avoid injury or property damage, ensure that the path of the vehicle is clear before pushing vehicle.
  • Page 140 Test Procedures IQ SYSTEM TROUBLESHOOTING – TPS Reconnect the three-pin connector at the motor speed sensor. Using a multimeter set to 20 volts DC, place the black (–) probe on the battery no. 4 (4 x 12-Volt battery set) or battery no. 6 (6 x 8-Volt battery set) negative post and place the red (+) probe (with insulation-piercing probe) on the green wire between the three-pin connector and the motor speed sensor.
  • Page 141 IQ SYSTEM TROUBLESHOOTING – TPS Test Procedures 3.1. Access the Test menu and select FORWARD INPUT by using the SCROLL DISPLAY buttons. The IQDM should indicate OFF when the Forward/Reverse switch is in the NEUTRAL or REVERSE position. 3.2. Place the Forward/Reverse switch in the FORWARD position. The IQDM should indicate that FORWARD INPUT is ON.
  • Page 142 Test Procedures IQ SYSTEM TROUBLESHOOTING – TPS Place the Forward/Reverse switch in REVERSE. Using a multimeter set to 200 volts DC, place the black (–) probe on the orange/white wire terminal end (that was disconnected from the reverse buzzer) and place the red (+) probe on battery no.

  • Page 143: Battery Warning Light

    16 hours and the batteries are not sufficiently charged. This indicates an abnormal charge cycle. The charger and batteries should be checked by your Club Car distributor/dealer. • The battery warning light will repeatedly illuminate for 10 seconds, at 4 second intervals, during a charge cycle (with the DC plug still connected) if AC power to the charger is interrupted.

  • Page 144: Using The Cdm To Retrieve Data From The Onboard Computer

    Communication Display Module (CDM) IQ SYSTEM TROUBLESHOOTING – TPS window. See Figure 11-19, Page 11-35 for CDM features. Releasing the button when the desired code is displayed will display the data. Function codes and corresponding data are as follows: • F1 – Battery voltage: •...
  • Page 145 IQ SYSTEM TROUBLESHOOTING – TPS Communication Display Module (CDM) 4.4. If reading is still not obtained, go to the CDM Troubleshooting Guide on page 11-38. Once a value has been obtained in the display window, the CDM may be removed from its receiving position and the data reviewed.

  • Page 146: Cdm Troubleshooting Guide

    IQ SYSTEM TROUBLESHOOTING – TPS CDM TROUBLESHOOTING GUIDE Use the following chart as a starting point for troubleshooting problems with communication between the CDM and onboard computer. Contact your Club Car representative for more comprehensive information. OBC Will Not Communicate With The CDM...

  • Page 147: Section 12 - Iq System Troubleshooting - Mcor

    SECTION 12 – IQ SYSTEM TROUBLESHOOTING – MCOR DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. • Shorting of battery terminals can cause personal injury or death. – Do not place component mounting plate directly on top of batteries when removing or installing plate.

  • Page 148: Wiring Diagrams

    Wiring Diagrams IQ SYSTEM TROUBLESHOOTING – MCOR WIRING DIAGRAMS SP ADE #16 BLK/WHT #18 BLK 10-AMP FUSE SONIC LEFT #12 BLUE #12 BLUE #16 BROWN #18 BRN WELD TAILLIGHT #18 RED #16 WHITE #16 BLACK/WHITE #16 BLK/WHT #18 BLK #16 BROWN #18 BRN RIGHT #16 BROWN...
  • Page 149 IQ SYSTEM TROUBLESHOOTING – MCOR Wiring Diagrams #12 BLUE #18 WHITE #16 PINK TOW SWITCH DIODE #16 R ED #16 BLUE #16 BLUE #18 R ED RECEPTACLE #10 R ED #10 BLACK #18 BRO WN/WHITE SINGLE P OSITION CONNECTOR #18 YELLOW 6 PIN GR OUP #18 LT BLUE CONNECTOR...
  • Page 150 Wiring Diagrams IQ SYSTEM TROUBLESHOOTING – MCOR USED WHEN THERE ARE LIGHTS BUT NO TURN S IGNAL. NORMALLY OPEN MOM ENTARY PUSH BU TTON FOR HORN 9-PIN #16 ORANGE CONNECT OR #16 BLUE/WHITE #16 WHITE #16 YELLOW SONIC #16 BROWN/WHITE WELD FLASHER UNIT...
  • Page 151 IQ SYSTEM TROUBLESHOOTING – MCOR Wiring Diagrams HEADLIGHT ASSEMBLY DC - DC HORN CONVERTER SONIC 20 AMP WELD #16 BLACK FUS E SONIC WELD #18 O RANGE DIODE #16 BLACK/WHITE #12 BLACK SON IC WELD #16 BLACK SON IC WELD CONNE CTS TO MAIN HARNESS.
  • Page 152 Wiring Diagrams IQ SYSTEM TROUBLESHOOTING – MCOR KEY SWITCH OP TIONAL BATTERY INDICATOR 9-PIN CONNECTOR. SONIC WELD CONNECTS TO MAIN HARNESS. SEE FIGURES 11-1 AND 11-2. #18 RED #16 BLUE #16 GREEN/RED #18 BLACK/YELLOW #18 BROWN/WHITE #18 BROWN/WHITE #18 ORANGE/WHITE #18 RED #18 YELLOW #18 GREEN...

  • Page 153: Troubleshooting

    TROUBLESHOOTING THE VEHICLE WITH THE IQDM Club Car recommends the use of the IQDM handset for troubleshooting vehicles equipped with the IQ electrical system. Troubleshooting Guide 1 is to be used in conjunction with the IQDM handset. See IQ Display Module (IQDM) and IQDM-P Diagnostics: IQ System on page 15-1 for operating instructions.

  • Page 154: Troubleshooting Guide 1

    Troubleshooting IQ SYSTEM TROUBLESHOOTING – MCOR If an IQDM handset is unavailable, the technician should proceed to Troubleshooting Guide 2. TROUBLESHOOTING GUIDE 1 The following troubleshooting guide is intended for use with an IQDM handset. See following NOTE. NOTE: Before troubleshooting the vehicle, check the diagnostic history from the Special Diagnostics Menu. Note any fault codes.
  • Page 155 IQ SYSTEM TROUBLESHOOTING – MCOR Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Disconnect the batteries and allow the speed controller capacitors to discharge. See WARNING “To avoid unintentionally Speed controller logic malfunction starting...” in General Warnings on page 1-1.
  • Page 156 Troubleshooting IQ SYSTEM TROUBLESHOOTING – MCOR TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Diagnostic Menu – MAIN COIL FAULT fault Replace solenoid. See Solenoid Removal on code or Diagnostic Menu – MAIN DROPOUT Solenoid coil has failed in an open condition page 17-13.

  • Page 157: Troubleshooting Guide 2

    IQ SYSTEM TROUBLESHOOTING – MCOR Troubleshooting TROUBLESHOOTING GUIDE 2 TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Batteries – Batteries discharged Charge batteries Check vehicle wiring. See Wiring Diagrams Batteries – Battery connections on page 12-2. Battery charger is connected to the vehicle Disconnect the battery charger from the –...
  • Page 158 Troubleshooting IQ SYSTEM TROUBLESHOOTING – MCOR TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Test Procedure 21 – Motor Speed Sensor on Speed sensor disconnected or failed page 12-34 To change the programmed top speed of the Incorrect speed setting vehicle, an IQDM-P handset must be used Check vehicle wiring.

  • Page 159: Test Procedures

    IQ SYSTEM TROUBLESHOOTING – MCOR Test Procedures TEST PROCEDURES Using the following procedures, the entire IQ electrical system can be tested without major disassembly of the vehicle. WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.
  • Page 160 Test Procedures IQ SYSTEM TROUBLESHOOTING – MCOR 21 – Motor Speed Sensor 22 – Solenoid Continuity 23 – Forward/Reverse Rocker Switch 24 – Reverse Buzzer 25 – Rebooting the Onboard Computer 26 – Battery Warning Light TEST PROCEDURE 1 – Batteries / Voltage Check See General Warnings on page 1-1.
  • Page 161 IQ SYSTEM TROUBLESHOOTING – MCOR Test Procedures WAVETEK 1000 WAVETEK 1000 2000 200k 2000 200k 200nA 200nA 1000 --- FUSED 750V 1000 --- FUSED 750V (Viewed from driver side of vehicle) (Viewed from driver side of vehicle) 1. RED probe to battery no. 1 (+). 1.
  • Page 162 Test Procedures IQ SYSTEM TROUBLESHOOTING – MCOR 6.2. Using a multimeter set to 200 volts DC, place the black (–) probe on the battery no. 4 (4 x 12-Volt battery set) or battery no. 6 (6 x 8-Volt battery set) negative post and place the red (+) probe (with insulation-piercing probe) on the red 18-gauge wire (harness side of six-pin connector).
  • Page 163 IQ SYSTEM TROUBLESHOOTING – MCOR Test Procedures WARNING • The key switch should be placed in the OFF position and left in the OFF position for the duration of this test. Connect the IQDM to the vehicle. Access the Test menu and select THROTTLE % by using the SCROLL DISPLAY buttons. The IQDM should indicate 0 % with the pedal not pressed.
  • Page 164 Test Procedures IQ SYSTEM TROUBLESHOOTING – MCOR 8.4. With the accelerator pedal fully up (not pressed), the multimeter should read approximately 1k ohms. 8.5. Slowly press the accelerator pedal while monitoring the multimeter. The resistance should rise as the pedal is pressed. When the pedal is all the way to the floor, the multimeter should indicate between 5.67k ohms and 7.43k ohms.
  • Page 165 IQ SYSTEM TROUBLESHOOTING – MCOR Test Procedures TEST PROCEDURE 6 – Tow/Run Switch See General Warnings on page 1-1. Tow/Run Switch Test with the IQDM Handset With the Tow/Run switch in the RUN position, connect the IQDM to the vehicle. Immediately after the IQDM is connected to the vehicle, the screen should display a copyright notice and the IQDM model number.
  • Page 166 Test Procedures IQ SYSTEM TROUBLESHOOTING – MCOR TEST PROCEDURE 7 – Battery Pack Voltage (Under Load) See General Warnings on page 1-1. Be sure the batteries are fully charged and that the electrolyte level is correct in all cells. Connect the tester leads to the positive (+) post of battery no.1 and negative (–) post of battery no. 4 (Figure 12-11, Page 12-20 and Figure 12-12, Page 12-20) or battery no.
  • Page 167 IQ SYSTEM TROUBLESHOOTING – MCOR Test Procedures A reading of 32-46 volts indicates discharged or failed batteries. Each battery should be checked with a multimeter while under load. A reading of 32 volts or less will not activate discharge machine. If the voltage of the batteries is below 32 volts, the batteries are deeply discharged or have failed.
  • Page 168 Test Procedures IQ SYSTEM TROUBLESHOOTING – MCOR Turn the key switch to the OFF position and place the Forward/Reverse switch in the NEUTRAL position. Test the key switch. 4.1. Remove the instrument panel. See Key Switch Removal on page 17-1. 4.2.
  • Page 169 IQ SYSTEM TROUBLESHOOTING – MCOR Test Procedures TEST PROCEDURE 9 – 16-Pin Connector See General Warnings on page 1-1. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-3. Disconnect the 16-pin connector from the speed controller. Inspect terminal ends inside plug to ensure they are in position and seated in plug housing.
  • Page 170 Test Procedures IQ SYSTEM TROUBLESHOOTING – MCOR TEST PROCEDURE 10 – Pins 1, 2, and 3 See General Warnings on page 1-1. Pins 1, 2, and 3 in the 16-pin connector provide a connection point from the MCOR potentiometer to the speed controller.
  • Page 171 IQ SYSTEM TROUBLESHOOTING – MCOR Test Procedures TEST PROCEDURE 11 – Pin 5 See General Warnings on page 1-1. Pin 5 in the 16-pin connector provides a connection point for the solenoid lockout circuit from the onboard computer to the speed controller. Disconnect the batteries and discharge the controller.
  • Page 172 Test Procedures IQ SYSTEM TROUBLESHOOTING – MCOR – Tow/Run switch for proper operation. See Test Procedure 6 – Tow/Run Switch on page 12-19. TEST PROCEDURE 12 – Pin 6 See General Warnings on page 1-1. Pin 6 in the 16-pin connector provides a connection point for the MCOR limit switch to the speed controller. Disconnect the batteries and discharge the controller.
  • Page 173 IQ SYSTEM TROUBLESHOOTING – MCOR Test Procedures 12. The multimeter should indicate zero volts when the accelerator pedal is not pressed. 13. If any other reading is obtained, check the following items: – Continuity of the wires in the wire harness –...
  • Page 174 Test Procedures IQ SYSTEM TROUBLESHOOTING – MCOR Figure 12-17 Pin 7 Test TEST PROCEDURE 14 – Pins 8 and 16 See General Warnings on page 1-1. Pins 8 and 16 in the 16-pin connector provide a connection point for the Forward/Reverse rocker switch to the speed controller.
  • Page 175 IQ SYSTEM TROUBLESHOOTING – MCOR Test Procedures 12. Place the Forward/Reverse switch in the REVERSE position. The multimeter should indicate full battery voltage (approximately 48 volts). 13. If any other reading is obtained, check the following items: – Continuity of the wires in the wire harness –...
  • Page 176 Test Procedures IQ SYSTEM TROUBLESHOOTING – MCOR WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with Tow/Run switch in RUN position) Figure 12-19 Pin 9 Test With the Tow/Run switch in the RUN position, the multimeter should indicate full battery voltage (approximately 48 volts).
  • Page 177 IQ SYSTEM TROUBLESHOOTING – MCOR Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with Tow/Run switch in RUN and key switch in the ON position) Figure 12-20 Pin 10 Test With the key switch in the ON position, the multimeter should indicate full battery voltage (approximately 48 volts). With the key switch in the OFF position, the reading should be zero volts.
  • Page 178 Test Procedures IQ SYSTEM TROUBLESHOOTING – MCOR Figure 12-21 Pin 12 Test The solenoid should click when the key switch is placed in the ON position. If any other activity is observed, check the following items: – Continuity of the wires in the wire harness –...
  • Page 179 IQ SYSTEM TROUBLESHOOTING – MCOR Test Procedures TEST PROCEDURE 19 – Onboard Computer Gray Wire See General Warnings on page 1-1. With batteries connected and the DC cord disconnected, pull back on the boot (1) on the gray wire (2) connection at the OBC (3) (Figure 12-22, Page 12-33).
  • Page 180 Test Procedures IQ SYSTEM TROUBLESHOOTING – MCOR TEST PROCEDURE 21 – Motor Speed Sensor See General Warnings on page 1-1. Motor Speed Sensor Test with the IQDM Handset CAUTION • Perform the following procedure only on a level surface. To avoid injury or property damage, ensure that the path of the vehicle is clear before pushing vehicle.
  • Page 181 IQ SYSTEM TROUBLESHOOTING – MCOR Test Procedures Reconnect the three-pin connector at the motor speed sensor. Using a multimeter set to 20 volts DC, place the black (–) probe on the battery no. 4 (4 x 12-Volt battery set) or battery no. 6 (6 x 8-Volt battery set) negative post and place the red (+) probe (with insulation-piercing probe) on the green wire between the three-pin connector and the motor speed sensor.
  • Page 182 Test Procedures IQ SYSTEM TROUBLESHOOTING – MCOR 3.1. Access the Test menu and select FORWARD INPUT by using the SCROLL DISPLAY buttons. The IQDM should indicate OFF when the Forward/Reverse switch is in the NEUTRAL or REVERSE position. 3.2. Place the Forward/Reverse switch in the FORWARD position. The IQDM should indicate that FORWARD INPUT is ON.
  • Page 183 IQ SYSTEM TROUBLESHOOTING – MCOR Test Procedures Place the Forward/Reverse switch in REVERSE. Using a multimeter set to 200 volts DC, place the black (–) probe on the orange/white wire terminal end (that was disconnected from the reverse buzzer) and place the red (+) probe on battery no.

  • Page 184: Battery Warning Light

    16 hours and the batteries are not sufficiently charged. This indicates an abnormal charge cycle. The charger and batteries should be checked by your Club Car distributor/dealer. • The battery warning light will repeatedly illuminate for 10 seconds, at 4 second intervals, during a charge cycle (with the DC plug still connected) if AC power to the charger is interrupted.

  • Page 185: Communication Display Module (Cdm)

    Func3 - Func4 - Last charge termination type (1 = Incomplete, 2 = DVDT, 4 = Normal, 8 = Max. timer). POWER Club Car PART #17075 1. Low Battery 2. Display Window 3. Function Button 2500-19200-10300 Figure 12-23 CDM The CDM can be used to retrieve from the onboard computer four important items of information that can be useful in troubleshooting the IQ System vehicle.

  • Page 186: Using The Cdm To Retrieve Data From The Onboard Computer

    CDM TROUBLESHOOTING GUIDE Use the following chart as a starting point for troubleshooting problems with communication between the CDM and onboard computer. Contact your Club Car representative for more comprehensive information. Page 12-40 2009-2011 Electric Precedent Maintenance and Service Manual...
  • Page 187 IQ SYSTEM TROUBLESHOOTING – MCOR CDM Troubleshooting Guide OBC Will Not Communicate With The CDM CDM battery Failed CDM unit Failed OBC is discharged Replace CDM battery Replace CDM Replace OBC Failed Dash Light Replace Dash Light OBC program is "locked-up"...

  • Page 189: Section 13 - Excel System Troubleshooting - Tps

    SECTION 13 – EXCEL SYSTEM TROUBLESHOOTING – TPS DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. • Shorting of battery terminals can cause personal injury or death. – Do not place component mounting plate directly on top of batteries when removing or installing plate.

  • Page 190: Features

    General Information EXCEL SYSTEM TROUBLESHOOTING – TPS • The programmed speed of the Excel vehicle can now range from 5 to 19.2 mph with fine adjustments in 0.1 mph increments. • Excel provides mileage readings. • Excel has more diagnostics available. •...

  • Page 191: Wiring Diagrams

    EXCEL SYSTEM TROUBLESHOOTING – TPS Wiring Diagrams WIRING DIAGRAMS KEY SWITCH OP TIONAL BATTERY INDICATOR 9-PIN CONNECTOR. SONIC WELD CONNECTS TO MAIN HARNESS. SEE FIGURES 11-1 AND 11-2. #18 RED #16 BLUE #16 GREEN/RED #18 BLACK/YELLOW #18 BROWN/WHITE #18 BROWN/WHITE #18 ORANGE/WHITE #18 RED #18 YELLOW...
  • Page 192 Wiring Diagrams EXCEL SYSTEM TROUBLESHOOTING – TPS USED WHEN THERE ARE LIGHTS BUT NO TURN S IGNAL. NORMALLY OPEN MOM ENTARY PUSH BU TTON FOR HORN 9-PIN #16 ORANGE CONNECT OR #16 BLUE/WHITE #16 WHITE #16 YELLOW SONIC #16 BROWN/WHITE WELD FLASHER UNIT...
  • Page 193 EXCEL SYSTEM TROUBLESHOOTING – TPS Wiring Diagrams HEADLIGHT ASSEMBLY DC - DC HORN CONVERTER SONIC 20 AMP WELD #16 BLACK FUS E SONIC WELD #18 O RANGE DIODE #16 BLACK/WHITE #12 BLACK SON IC WELD #16 BLACK SON IC WELD CONNE CTS TO MAIN HARNESS.
  • Page 194 Wiring Diagrams EXCEL SYSTEM TROUBLESHOOTING – TPS W77 16_RED_WHT W35 18_GR N W77 16_RED_WHT SW_7 W39 18_B RN_WH T W10 18_BL K_WH T INTERF ACES TO SMART BOX SW_1 W66 18_L T_BL U W09 18_BLK W08 18_Y EL W102 16_BL U W36 18_GRN W07 18_RED W20 18_Y EL_B LK...
  • Page 195 EXCEL SYSTEM TROUBLESHOOTING – TPS Wiring Diagrams W77 16_RED_WHT W91 18_BL U_WHT SOLENOID W30 16_P NK W66 18_L T_BL U YE L W111 18_YEL RE D W29 18_RED W38 18_BRN_WHT W103 18_WHT BL U W06 18_L T_BL U ONBOARD COMPUTER TO (B-) CONTRO LLER TO (B-) BA TTER Y W08 18_Y EL...

  • Page 196: Troubleshooting

    TROUBLESHOOTING THE VEHICLE WITH THE IQDM Club Car recommends the use of the IQDM handset for troubleshooting vehicles equipped with the Excel electrical system. Troubleshooting Guide 1 is to be used in conjunction with the IQDM handset. See IQ Display Module (IQDM) and IQDM-P Diagnostics: Excel System on page 16-1 for operating instructions.
  • Page 197 EXCEL SYSTEM TROUBLESHOOTING – TPS Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected motor speed sensor Repair and/or connect the three-pin connector or broken wire to the motor speed sensor Test Menu – SPEED PULSES menu item indicates that speed pulses are OFF when Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector...
  • Page 198 Troubleshooting EXCEL SYSTEM TROUBLESHOOTING – TPS TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected six-pin connector at the Repair and/or connect the six-pin connector to throttle position sensor or broken wire the throttle position sensor Diagnostic Menu – THROTTLE FAULT fault Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector code...

  • Page 199: Troubleshooting Guide 2

    EXCEL SYSTEM TROUBLESHOOTING – TPS Troubleshooting TROUBLESHOOTING GUIDE 2 TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Batteries – Batteries discharged Charge batteries Check vehicle wiring. See Wiring Diagrams Batteries – Battery connections on page 13-3. Battery charger is connected to the vehicle Disconnect the battery charger from the –...
  • Page 200 Troubleshooting EXCEL SYSTEM TROUBLESHOOTING – TPS TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Test Procedure 21 – Motor Speed Sensor on Speed sensor disconnected or failed page 13-31 To change the programmed top speed of the Incorrect speed setting vehicle, an IQDM-P handset must be used Check vehicle wiring.

  • Page 201: Test Procedures

    EXCEL SYSTEM TROUBLESHOOTING – TPS Test Procedures TEST PROCEDURES Using the following procedures, the entire electrical system can be tested without major disassembly of the vehicle. WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.
  • Page 202 Test Procedures EXCEL SYSTEM TROUBLESHOOTING – TPS 21 – Motor Speed Sensor 22 – Solenoid Continuity 23 – Forward/Reverse Rocker Switch 24 – Reverse Buzzer 25 – Rebooting the Onboard Computer 26 – Battery Warning Light TEST PROCEDURE 1 – Batteries / Voltage Check See General Warnings on page 1-1.
  • Page 203 EXCEL SYSTEM TROUBLESHOOTING – TPS Test Procedures TEST PROCEDURE 2 – Onboard Computer Solenoid Lockout Circuit See General Warnings on page 1-1. The solenoid lockout circuit disables the vehicle when the battery charger is plugged into the vehicle. Use the following procedure to test the solenoid lockout circuit: With batteries connected, place the Tow/Run switch in the RUN position.
  • Page 204 Test Procedures EXCEL SYSTEM TROUBLESHOOTING – TPS – A reading of 200 to 250 ohms should be obtained for factory-installed solenoids (Figure 13-8, Page 13-16). If not, replace the solenoid. – A reading of 180 to 190 ohms should be obtained for service replacement solenoids (Figure 13-9, Page 13-16).
  • Page 205 EXCEL SYSTEM TROUBLESHOOTING – TPS Test Procedures on the purple/white wire at a point close to the six-pin connector at the throttle position sensor. The reading should be approximately 48-50 volts (full battery voltage). If reading is zero volts, check the purple/white wire continuity from the six-pin connector at the sensor to the 16-pin connector at the speed controller.
  • Page 206 Test Procedures EXCEL SYSTEM TROUBLESHOOTING – TPS 4.3. Check continuity on A1 and A2 motor terminal posts and continuity of the F1 and F2 motor terminal posts. Also, check continuity of all motor wires. See Section 20 – Motor (Model EJ4-4001 and EJ8-4001A). TEST PROCEDURE 6 –...
  • Page 207 EXCEL SYSTEM TROUBLESHOOTING – TPS Test Procedures TEST PROCEDURE 7 – Battery Pack Voltage (Under Load) See General Warnings on page 1-1. Be sure the batteries are fully charged and that the electrolyte level is correct in all cells. Connect the tester leads to the positive (+) post of battery no.1 and negative (–) post of battery no. 4 (Figure 13-10, Page 13-19) or battery no.
  • Page 208 Test Procedures EXCEL SYSTEM TROUBLESHOOTING – TPS TEST PROCEDURE 8 – Key Switch and Throttle Position Sensor Limit Switch Circuit See General Warnings on page 1-1. Key Switch and Throttle Position Sensor Limit Switch Circuit Test with the IQDM Handset Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack.
  • Page 209 EXCEL SYSTEM TROUBLESHOOTING – TPS Test Procedures 4.5. If any other reading is obtained, replace the key switch. See Key Switch Removal on page 17-1. 4.6. If the key switch operates as described in the previous steps, install the instrument panel in the reverse order of removal and proceed to the following step.
  • Page 210 Test Procedures EXCEL SYSTEM TROUBLESHOOTING – TPS If the results of any of the referenced procedures are different from those described in the procedure, check the continuity of the wires in the wire harness and test the connected components with the appropriate test procedures. See Index of Test Procedures.
  • Page 211 EXCEL SYSTEM TROUBLESHOOTING – TPS Test Procedures Disconnect the 16-pin connector at the speed controller. Using a multimeter set for 200 volts DC, insert the red (+) probe of the multimeter into pin 5 (light blue wire) of the 16-pin connector. See following CAUTION. Using an alligator clip, connect the black (–) probe to the B– terminal of the speed controller (Figure 13-12, Page 13-23).
  • Page 212 Test Procedures EXCEL SYSTEM TROUBLESHOOTING – TPS TEST PROCEDURE 12 – Pin 6 See General Warnings on page 1-1. Pin 6 in the 16-pin connector provides a connection point for the throttle position sensor limit switch to the speed controller. A 48 volt signal is sent through this wire when the accelerator pedal is pressed, completing the circuit inside the throttle position sensor.
  • Page 213 EXCEL SYSTEM TROUBLESHOOTING – TPS Test Procedures Figure 13-13 Pin 7 Test TEST PROCEDURE 14 – Pins 8 and 16 See General Warnings on page 1-1. Pins 8 and 16 in the 16-pin connector provide a connection point for the Forward/Reverse rocker switch to the speed controller.
  • Page 214 Test Procedures EXCEL SYSTEM TROUBLESHOOTING – TPS 12. Place the Forward/Reverse switch in the REVERSE position. The multimeter should indicate full battery voltage (approximately 48 volts). 13. If any other reading is obtained, check the following items: – Continuity of the wires in the wire harness –...
  • Page 215 EXCEL SYSTEM TROUBLESHOOTING – TPS Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with Tow/Run switch in RUN position) Figure 13-15 Pin 9 Test With the Tow/Run switch in the RUN position, the multimeter should indicate full battery voltage (approximately 48 volts).
  • Page 216 Test Procedures EXCEL SYSTEM TROUBLESHOOTING – TPS WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with Tow/Run switch in RUN and key switch in the ON position) Figure 13-16 Pin 10 Test Place the Tow/Run switch in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-3.
  • Page 217 EXCEL SYSTEM TROUBLESHOOTING – TPS Test Procedures CAUTION • Do not fully insert probes into the 16-pin plug. Doing so can result in a poor connection. Place the Tow/Run switch in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-3.
  • Page 218 Test Procedures EXCEL SYSTEM TROUBLESHOOTING – TPS – Black wire terminal socket in the charger receptacle. – Onboard computer gray wire. See Test Procedure 19 – Onboard Computer Gray Wire on page 13-30. – Red wire at the charger receptacle. See Test Procedure 20 – Voltage at Charger Receptacle Red Wire Socket on page 13-30.
  • Page 219 EXCEL SYSTEM TROUBLESHOOTING – TPS Test Procedures TEST PROCEDURE 21 – Motor Speed Sensor See General Warnings on page 1-1. Motor Speed Sensor Test with the IQDM Handset CAUTION • Perform the following procedure only on a level surface. To avoid injury or property damage, ensure that the path of the vehicle is clear before pushing vehicle.
  • Page 220 Test Procedures EXCEL SYSTEM TROUBLESHOOTING – TPS Reconnect the three-pin connector at the motor speed sensor. Using a multimeter set to 20 volts DC, place the black (–) probe on the battery no. 4 (4 x 12-Volt battery set) or battery no. 6 (6 x 8-Volt battery set) negative post and place the red (+) probe (with insulation-piercing probe) on the green wire between the three-pin connector and the motor speed sensor.
  • Page 221 EXCEL SYSTEM TROUBLESHOOTING – TPS Test Procedures 3.1. Access the Test menu and select FORWARD INPUT by using the SCROLL DISPLAY buttons. The IQDM should indicate OFF when the Forward/Reverse switch is in the NEUTRAL or REVERSE position. 3.2. Place the Forward/Reverse switch in the FORWARD position. The IQDM should indicate that FORWARD INPUT is ON.
  • Page 222 Test Procedures EXCEL SYSTEM TROUBLESHOOTING – TPS Place the Forward/Reverse switch in REVERSE. Using a multimeter set to 200 volts DC, place the black (–) probe on the orange/white wire terminal end (that was disconnected from the reverse buzzer) and place the red (+) probe on battery no.

  • Page 223: Battery Warning Light

    16 hours and the batteries are not sufficiently charged. This indicates an abnormal charge cycle. The charger and batteries should be checked by your Club Car distributor/dealer. • The battery warning light will repeatedly illuminate for 10 seconds, at 4 second intervals, during a charge cycle (with the DC plug still connected) if AC power to the charger is interrupted.

  • Page 224: Using The Cdm To Retrieve Data From The Onboard Computer

    Communication Display Module (CDM) EXCEL SYSTEM TROUBLESHOOTING – TPS in the window. See Figure 13-19, Page 13-35 for CDM features. Releasing the button when the desired code is displayed will display the data. Function codes and corresponding data are as follows: •...
  • Page 225 EXCEL SYSTEM TROUBLESHOOTING – TPS Communication Display Module (CDM) 4.4. If reading is still not obtained, go to the CDM Troubleshooting Guide on page 13-38. Once a value has been obtained in the display window, the CDM may be removed from its receiving position and the data reviewed.

  • Page 226: Cdm Troubleshooting Guide

    EXCEL SYSTEM TROUBLESHOOTING – TPS CDM TROUBLESHOOTING GUIDE Use the following chart as a starting point for troubleshooting problems with communication between the CDM and onboard computer. Contact your Club Car representative for more comprehensive information. OBC Will Not Communicate With The CDM...

  • Page 227: Section 14 - Excel System Troubleshooting - Mcor

    SECTION 14 – EXCEL SYSTEM TROUBLESHOOTING – MCOR DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. • Shorting of battery terminals can cause personal injury or death. – Do not place component mounting plate directly on top of batteries when removing or installing plate.

  • Page 228: Features

    General Information EXCEL SYSTEM TROUBLESHOOTING – MCOR • The programmed speed of the Excel vehicle can now range from 5 to 19.2 mph with fine adjustments in 0.1 mph increments. • Excel provides mileage readings. • Excel has more diagnostics available. •...

  • Page 229: Wiring Diagrams

    EXCEL SYSTEM TROUBLESHOOTING – MCOR Wiring Diagrams WIRING DIAGRAMS KEY SWITCH OP TIONAL BATTERY INDICATOR 9-PIN CONNECTOR. SONIC WELD CONNECTS TO MAIN HARNESS. SEE FIGURES 11-1 AND 11-2. #18 RED #16 BLUE #16 GREEN/RED #18 BLACK/YELLOW #18 BROWN/WHITE #18 BROWN/WHITE #18 ORANGE/WHITE #18 RED #18 YELLOW...
  • Page 230 Wiring Diagrams EXCEL SYSTEM TROUBLESHOOTING – MCOR USED WHEN THERE ARE LIGHTS BUT NO TURN S IGNAL. NORMALLY OPEN MOM ENTARY PUSH BU TTON FOR HORN 9-PIN #16 ORANGE CONNECT OR #16 BLUE/WHITE #16 WHITE #16 YELLOW SONIC #16 BROWN/WHITE WELD FLASHER UNIT...
  • Page 231 EXCEL SYSTEM TROUBLESHOOTING – MCOR Wiring Diagrams HEADLIGHT ASSEMBLY DC - DC HORN CONVERTER SONIC 20 AMP WELD #16 BLACK FUS E SONIC WELD #18 O RANGE DIODE #16 BLACK/WHITE #12 BLACK SON IC WELD #16 BLACK SON IC WELD CONNE CTS TO MAIN HARNESS.
  • Page 232 Wiring Diagrams EXCEL SYSTEM TROUBLESHOOTING – MCOR #16 BLK/WHT #18 BLK #16 BRO WN LEFT #18 BRN TAILLIGHT #18 RED #16 WHITE #16 BLACK/WHITE #18 BLK #16 BLK/WHT RIGHT CONNECTS TO #16 BRO WN #16 BRO WN #18 BRN TAILLIGHT 12 POSITION CONNECTOR #16 YELLOW...
  • Page 233 EXCEL SYSTEM TROUBLESHOOTING – MCOR Wiring Diagrams 6_ RED 6_ BLK 10 _O RG CONTROLLER 6_ GRN 10 _O RG W03 18_L T GREE N V OUT W05 18_RED V OC 10 _BLU 6_ WHT 12_BL UE WD1034035B-R Figure 14-5 Wiring Diagram – Excel System with MCOR (Continued) 2009-2011 Electric Precedent Maintenance and Service Manual Page 14-7...

  • Page 234: Troubleshooting

    TROUBLESHOOTING THE VEHICLE WITH THE IQDM Club Car recommends the use of the IQDM handset for troubleshooting vehicles equipped with the Excel electrical system. Troubleshooting Guide 1 is to be used in conjunction with the IQDM handset. See IQ Display Module (IQDM) and IQDM-P Diagnostics: Excel System on page 16-1 for operating instructions.
  • Page 235 EXCEL SYSTEM TROUBLESHOOTING – MCOR Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected motor speed sensor Repair and/or connect the three-pin connector or broken wire to the motor speed sensor Test Menu – SPEED PULSES menu item indicates that speed pulses are OFF when Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector...
  • Page 236 Troubleshooting EXCEL SYSTEM TROUBLESHOOTING – MCOR TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected three-pin connector at Repair and/or connect the three-pin connector the MCOR or broken wire to the MCOR Diagnostic Menu – THROTTLE FAULT fault Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector code...

  • Page 237: Troubleshooting Guide 2

    EXCEL SYSTEM TROUBLESHOOTING – MCOR Troubleshooting TROUBLESHOOTING GUIDE 2 TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Batteries – Batteries discharged Charge batteries Check vehicle wiring. See Wiring Diagrams Batteries – Battery connections on page 14-3. Battery charger is connected to the vehicle Disconnect the battery charger from the –...
  • Page 238 Troubleshooting EXCEL SYSTEM TROUBLESHOOTING – MCOR TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Test Procedure 21 – Motor Speed Sensor on Speed sensor disconnected or failed page 14-34 To change the programmed top speed of the Incorrect speed setting vehicle, an IQDM-P handset must be used Check vehicle wiring.

  • Page 239: Test Procedures

    EXCEL SYSTEM TROUBLESHOOTING – MCOR Test Procedures TEST PROCEDURES Using the following procedures, the entire electrical system can be tested without major disassembly of the vehicle. WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.
  • Page 240 Test Procedures EXCEL SYSTEM TROUBLESHOOTING – MCOR 21 – Motor Speed Sensor 22 – Solenoid Continuity 23 – Forward/Reverse Rocker Switch 24 – Reverse Buzzer 25 – Rebooting the Onboard Computer 26 – Battery Warning Light TEST PROCEDURE 1 – Batteries / Voltage Check See General Warnings on page 1-1.
  • Page 241 EXCEL SYSTEM TROUBLESHOOTING – MCOR Test Procedures TEST PROCEDURE 2 – Onboard Computer Solenoid Lockout Circuit See General Warnings on page 1-1. The solenoid lockout circuit disables the vehicle when the battery charger is plugged into the vehicle. Use the following procedure to test the solenoid lockout circuit: With batteries connected, place the Tow/Run switch in the RUN position.
  • Page 242 Test Procedures EXCEL SYSTEM TROUBLESHOOTING – MCOR – A reading of 200 to 250 ohms should be obtained for factory-installed solenoids (Figure 14-8, Page 14-16). If not, replace the solenoid. – A reading of 180 to 190 ohms should be obtained for service replacement solenoids (Figure 14-9, Page 14-16).
  • Page 243 EXCEL SYSTEM TROUBLESHOOTING – MCOR Test Procedures WARNING • The key switch should be placed in the OFF position and left in the OFF position for the duration of this test. With the batteries connected, place Tow/Run switch in RUN. Using a multimeter set to 200 volts DC, place red (+) probe on battery no.
  • Page 244 Test Procedures EXCEL SYSTEM TROUBLESHOOTING – MCOR TEST PROCEDURE 5 – A1 and A2 Motor Voltage See General Warnings on page 1-1. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands under the frame rails just forward of each spring mount.
  • Page 245 EXCEL SYSTEM TROUBLESHOOTING – MCOR Test Procedures TEST PROCEDURE 6 – Tow/Run Switch See General Warnings on page 1-1. Tow/Run Switch Test with the IQDM Handset With the Tow/Run switch in the RUN position, connect the IQDM to the vehicle. Immediately after the IQDM is connected to the vehicle, the screen should display a copyright notice and the IQDM model number.
  • Page 246 Test Procedures EXCEL SYSTEM TROUBLESHOOTING – MCOR TEST PROCEDURE 7 – Battery Pack Voltage (Under Load) See General Warnings on page 1-1. Be sure the batteries are fully charged and that the electrolyte level is correct in all cells. Connect the tester leads to the positive (+) post of battery no.1 and negative (–) post of battery no. 4 (Figure 14-10, Page 14-20) or battery no.
  • Page 247 EXCEL SYSTEM TROUBLESHOOTING – MCOR Test Procedures Test the key switch. 4.1. Access the Test menu and select KEY INPUT by using the SCROLL DISPLAY buttons. The IQDM should indicate OFF when the key switch is in the OFF position. 4.2.
  • Page 248 Test Procedures EXCEL SYSTEM TROUBLESHOOTING – MCOR WARNING • The Forward/Reverse switch must be in the neutral position to avoid personal injury due to contact with rotating wheels. 5.2. With Tow/Run switch in the RUN position, key switch in the ON position, and Forward/Reverse rocker switch in the NEUTRAL position, the voltage reading should be zero volts.
  • Page 249 EXCEL SYSTEM TROUBLESHOOTING – MCOR Test Procedures SPEED CONTROLLER 16-PIN CONNECTOR WIRE TEST PROCEDURE Pin 1 – White (18-gauge) Test Procedure 10 – Pins 1, 2, and 3 on page 14-23 Pin 2 – Yellow (18-gauge) Also for Pin 3 Test continuity of wire and perform Test Procedure 21 – Motor Speed Sensor on page 14-34 Pin 3 –...
  • Page 250 Test Procedures EXCEL SYSTEM TROUBLESHOOTING – MCOR WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 20k Ohm Setting (reading with pedal not pressed) Figure 14-12 Pins 1, 2, and 3 Test Using a multimeter set for 20k ohms, insert the red (+) probe of the multimeter into pin 2 (yellow wire) at the 16-pin connector.
  • Page 251 EXCEL SYSTEM TROUBLESHOOTING – MCOR Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with OBC powered-up and battery charger disconnected) Figure 14-13 Pin 5 Test Place the Tow/Run switch in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-3.
  • Page 252 Test Procedures EXCEL SYSTEM TROUBLESHOOTING – MCOR WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with OBC powered-up and accelerator pedal pressed) Figure 14-14 Pin 6 Test Using a multimeter set for 200 volts DC, insert the red (+) probe of the multimeter into pin 6 (green wire) of the 16-pin connector.
  • Page 253 EXCEL SYSTEM TROUBLESHOOTING – MCOR Test Procedures TEST PROCEDURE 13 – Pin 7 See General Warnings on page 1-1. Pin 7 in the 16-pin connector provides a connection point for the reverse buzzer to the speed controller. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-3.
  • Page 254 Test Procedures EXCEL SYSTEM TROUBLESHOOTING – MCOR TEST PROCEDURE 14 – Pins 8 and 16 See General Warnings on page 1-1. Pins 8 and 16 in the 16-pin connector provide a connection point for the Forward/Reverse rocker switch to the speed controller.
  • Page 255 EXCEL SYSTEM TROUBLESHOOTING – MCOR Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with Tow/Run switch in RUN and Forward/Reverse switch in FORWARD) Figure 14-16 Pins 8 and 16 Test TEST PROCEDURE 15 – Pin 9 See General Warnings on page 1-1.
  • Page 256 Test Procedures EXCEL SYSTEM TROUBLESHOOTING – MCOR WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with Tow/Run switch in RUN position) Figure 14-17 Pin 9 Test With the Tow/Run switch in the RUN position, the multimeter should indicate full battery voltage (approximately 48 volts).
  • Page 257 EXCEL SYSTEM TROUBLESHOOTING – MCOR Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with Tow/Run switch in RUN and key switch in the ON position) Figure 14-18 Pin 10 Test Place the Tow/Run switch in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-3.
  • Page 258 Test Procedures EXCEL SYSTEM TROUBLESHOOTING – MCOR CAUTION • Do not fully insert probes into the 16-pin plug. Doing so can result in a poor connection. Place the Tow/Run switch in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-3.
  • Page 259 EXCEL SYSTEM TROUBLESHOOTING – MCOR Test Procedures – Black wire terminal socket in the charger receptacle. – Onboard computer gray wire. See Test Procedure 19 – Onboard Computer Gray Wire on page 14-33. – Red wire at the charger receptacle. See Test Procedure 20 – Voltage at Charger Receptacle Red Wire Socket on page 14-33.
  • Page 260 Test Procedures EXCEL SYSTEM TROUBLESHOOTING – MCOR TEST PROCEDURE 21 – Motor Speed Sensor See General Warnings on page 1-1. Motor Speed Sensor Test with the IQDM Handset CAUTION • Perform the following procedure only on a level surface. To avoid injury or property damage, ensure that the path of the vehicle is clear before pushing vehicle.
  • Page 261 EXCEL SYSTEM TROUBLESHOOTING – MCOR Test Procedures Reconnect the three-pin connector at the motor speed sensor. Using a multimeter set to 20 volts DC, place the black (–) probe on the battery no. 4 (4 x 12-Volt battery set) or battery no. 6 (6 x 8-Volt battery set) negative post and place the red (+) probe (with insulation-piercing probe) on the green wire between the three-pin connector and the motor speed sensor.
  • Page 262 Test Procedures EXCEL SYSTEM TROUBLESHOOTING – MCOR 3.1. Access the Test menu and select FORWARD INPUT by using the SCROLL DISPLAY buttons. The IQDM should indicate OFF when the Forward/Reverse switch is in the NEUTRAL or REVERSE position. 3.2. Place the Forward/Reverse switch in the FORWARD position. The IQDM should indicate that FORWARD INPUT is ON.
  • Page 263 EXCEL SYSTEM TROUBLESHOOTING – MCOR Test Procedures Place the Forward/Reverse switch in REVERSE. Using a multimeter set to 200 volts DC, place the black (–) probe on the orange/white wire terminal end (that was disconnected from the reverse buzzer) and place the red (+) probe on battery no.

  • Page 264: Battery Warning Light

    16 hours and the batteries are not sufficiently charged. This indicates an abnormal charge cycle. The charger and batteries should be checked by your Club Car distributor/dealer. • The battery warning light will repeatedly illuminate for 10 seconds, at 4 second intervals, during a charge cycle (with the DC plug still connected) if AC power to the charger is interrupted.

  • Page 265: Using The Cdm To Retrieve Data From The Onboard Computer

    EXCEL SYSTEM TROUBLESHOOTING – MCOR Communication Display Module (CDM) in the window. See Figure 14-21, Page 14-38 for CDM features. Releasing the button when the desired code is displayed will display the data. Function codes and corresponding data are as follows: •...

  • Page 266: Cdm Troubleshooting Guide

    NOTE: The values of all four functions can be recalled by pressing and releasing the CDM button. CDM TROUBLESHOOTING GUIDE Use the following chart as a starting point for troubleshooting problems with communication between the CDM and onboard computer. Contact your Club Car representative for more comprehensive information. OBC Will Not Communicate With The CDM...

  • Page 267: Section 15 - Iq Display Module (Iqdm) And Iqdm-Pdiagnostics: Iq System

    SECTION 15 – IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. NOTE: For information specific to the IQDM-P handset programming features, see IQ Display Module Programmer (IQDM-P): IQ System on page 22-1.

  • Page 268: Menu Navigation

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Menu Navigation DIAGNOSTICS: IQ SYSTEM • Faults • Functions • Information • Programmer Setup In the event that the handset does not display any information, or the screen is difficult to read, refer to the IQDM troubleshooting procedures.

  • Page 269: Program (Iqdm-P Only)

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM Menu Navigation Figure 15-2 Handset Controls The following menus are accessible on the IQDM handset: PROGRAM (IQDM-P ONLY) The program menu allows the user to view and change custom speed controller settings. See Program Menu on page 22-2.

  • Page 270: Faults

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Monitor Menu DIAGNOSTICS: IQ SYSTEM FAULTS The faults menu displays all faults recorded by the speed controller since the history was last cleared. Each fault is listed only once, even if the fault has occurred multiple times. See Faults Menu on page 15-7. FUNCTIONS The functions menu allows the user to transfer all current settings from the speed controller to the handset and from the handset to the speed controller.

  • Page 271: Batt Voltage

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM Monitor Menu BATT VOLTAGE Displays the current battery voltage at the speed controller. HEATSINK Displays the temperature (in degrees Celsius) of the speed controller heatsink. During normal operating conditions, the heatsink temperature should be below 85 °C ±5 °C (185 °F ±9 °F). See following NOTE. NOTE: Improper brake adjustment can sometimes cause the operating current to be higher than normal.

  • Page 272: Forward Input

    “private speed mode”. In the event that “private speed mode” is locked out, the controller must be removed and shipped to Club Car before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 22-3.

  • Page 273: Faults Menu

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM Faults Menu FAULTS MENU The faults menu is accessed by using the up or down arrow to scroll to faults and pressing the right arrow key to activate the menu. Faults displayed in the faults menu will aid the trained technician in troubleshooting the vehicle. Faults displayed often indicate which components in the electrical system need to be tested.

  • Page 274: Hw Failsafe

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Faults Menu DIAGNOSTICS: IQ SYSTEM The speed controller, after detecting a fault, will respond in one or more of the following ways: • A. Reduce vehicle speed to zero by reducing armature current • B. Reduce vehicle speed to zero by reducing field current to zero •...

  • Page 275: Key Switch Sro (Static Return To Off)

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM Faults Menu Fault Recovery When a fault is detected by the speed controller, the speed controller will attempt to recover from the fault and resume normal operation. In the case of an intermittent problem such as a loose wiring connection, the controller may be able to recover and operate normally for a while, but the problem should be repaired before placing the vehicle in service.

  • Page 276: Throttle Fault 1

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Faults Menu DIAGNOSTICS: IQ SYSTEM if the vehicle had gone into sleep mode and the accelerator was pressed while the key switch was switched on. The key switch sro fault detect is by default disabled but can be enabled via the program menu KSI SRO ENABLE parameter. THROTTLE FAULT 1 If the throttle position sensor or MCOR (Motor Controller Output Regulator) voltage is less than 0.20 volts or greater than 4.80 volts, the controller detects a throttle fault 1 fault.

  • Page 277: Field Missing

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM Faults Menu FIELD MISSING If the speed controller is operating at a duty cycle of greater than 90% (almost full speed) and the field current is less than 3 amps, a field missing fault is detected by the speed controller. The HPD (High Pedal Detect) fault is detected if the accelerator pedal is already depressed when the key switch is turned to the ON position.

  • Page 278: Open Armature

    The max password tries fault is declared when the incorrect password fault has been declared several times. In the event that the max password tries fault is indicated, the speed controller must be removed and shipped to Club Car before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 22-3. See also Password Tries (IQDM-P only) on page 15-6.

  • Page 279: Functions Menu

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM Functions Menu FUNCTIONS MENU The functions menu is accessed by using the up or down arrow to scroll to functions and pressing the right arrow key to activate the menu. GET SETTINGS FROM CONTROLLER This function transfers all of the speed controller settings (except for “private speed mode”) from the vehicle speed controller to the handset.

  • Page 280: Write Settings To Controller

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Functions Menu DIAGNOSTICS: IQ SYSTEM Figure 15-3 Handset Executing Figure 15-4 Confirmation Message WRITE SETTINGS TO CONTROLLER This function transfers all of the speed controller settings (except for “private speed mode”) from the handset to the vehicle speed controller.

  • Page 281: Reset All Settings

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM Functions Menu Select write settings to controller. Press + on the change value button to confirm the operation. The handset will display an “executing...” message for the next few seconds while the controller settings are being stored in the handset’s memory (Figure 15-3, Page 15-14).

  • Page 282: Information

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Information DIAGNOSTICS: IQ SYSTEM The handset will display an “executing...” message for the next few seconds while the controller settings are being stored in the handset’s memory (Figure 15-3, Page 15-14). When the handset is finished resetting the speed controller settings, a confirmation message is displayed (Figure 15-6, Page 15-15).

  • Page 283: Programmer Setup

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM Programmer Setup PROGRAMMER SETUP The programmer setup menu selection allows the user to set the LCD display contrast, records the fault history of the handset, and displays information pertaining to the handset. PROGRAM This menu allows the user to adjust the contrast on the display screen.

  • Page 284: Iqdm And Iqdm-P Handset Troubleshooting

    IQ DISPLAY MODULE (IQDM) AND IQDM-P IQDM and IQDM-P Handset Troubleshooting DIAGNOSTICS: IQ SYSTEM IQDM AND IQDM-P HANDSET TROUBLESHOOTING In the event that the handset does not function as described in this manual, the following troubleshooting guide should be studied and the referenced test procedures should be performed to troubleshoot the handset. TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES...

  • Page 285: Test Procedures

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM Test Procedures TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Disconnect the IQDM cord from the vehicle. Handset malfunction Wait a few seconds and reconnect the handset to the vehicle Vehicle batteries – loose terminals or corrosion See Section 18 –...
  • Page 286 IQ DISPLAY MODULE (IQDM) AND IQDM-P Test Procedures DIAGNOSTICS: IQ SYSTEM Place the black (–) probe on each of the pins, one at a time, on the other plug of the adaptor. The multimeter should indicate continuity on only one pin. If any other reading is obtained, the adaptor must be replaced.
  • Page 287 IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM Test Procedures 4.3.1. Disconnect the square four-pin connector (3) from the speed controller. 4.3.2. Connect the handset cord to the handset. 4.3.3. Connect the other end of the handset cord (without the adapter) (4) to the four-pin connector of the speed controller (2) (Figure 15-8, Page 15-21).

  • Page 289: Section 16 - Iq Display Module (Iqdm) And Iqdm-Pdiagnostics: Excel System

    SECTION 16 – IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. NOTE: For information specific to the IQDM-P handset programming features, see IQ Display Module Programmer (IQDM-P): Excel System on page 23-1.

  • Page 290: Introductory Display

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Introductory Display DIAGNOSTICS: EXCEL SYSTEM INTRODUCTORY DISPLAY Immediately after the handset is connected to the vehicle, it begins loading the vehicle speed controller information. After a few seconds, the screen displays the following menu items: •...

  • Page 291: Menu Navigation

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM Menu Navigation MENU NAVIGATION The NAVIGATION BUTTON (1) is the four-arrow button located on the left side of the handset (Figure 16-3, Page 16-2). This button is used to navigate through and select menus. Pressing the up or down arrows allows the user to scroll through the menu items.

  • Page 292: Information

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Monitor Menu DIAGNOSTICS: EXCEL SYSTEM INFORMATION The information menu displays the model number, serial number, manufacturer date and software version of the speed controller. See Information on page 16-17. PROGRAMMER SETUP The programmer setup menu allows the user to set the LCD contrast, display the fault history of the programmer as well as various other information pertaining to the handset such as model number, serial number, OEM information, etc.

  • Page 293: Batt Aux Voltage

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM Monitor Menu BATT AUX VOLTAGE Displays the current battery voltage at the speed controller. TEMPERATURE (SAME AS HEATSINK IN IQ SYSTEM) Displays the temperature (in degrees Celsius) of the speed controller heatsink. During normal operating conditions, the heatsink temperature should be below 85 °C ±5 °C (185 °F ±9 °F).

  • Page 294: Foot Input

    “private speed mode”. In the event that “private speed mode” is locked out, the controller must be removed and shipped to Club Car before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 23-4.

  • Page 295: Odometer

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM Monitor Menu ODOMETER Displays approximate distance travelled in miles. VEHICLE SPEEDS (IQDM-P ONLY) Press right arrow to display programmed speeds for each speed setting. See Code A, Code B, and Code C on page 23-4.

  • Page 296: Faults Menu

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Faults Menu DIAGNOSTICS: EXCEL SYSTEM FAULTS MENU CAUTION • A failed motor will damage the controller. Always inspect the motor before replacing the controller. NOTE: The software is subject to frequent updates, and this manual spans many versions. Be aware that some faults listed in this manual may not display in the IQDM, indicating older software.

  • Page 297: Controller Fault

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM Faults Menu The vehicle speed controller should be checked for fault codes before any service is performed. The speed controller, after detecting a fault, will respond in one or more of the following ways: •...

  • Page 298: Hw Failsafe

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Faults Menu DIAGNOSTICS: EXCEL SYSTEM Fault Recovery When a fault is detected by the speed controller, the speed controller will attempt to recover from the fault and resume normal operation. In the case of an intermittent problem such as a loose wiring connection, the controller may be able to recover and operate normally for a while, but the problem should be repaired before placing the vehicle in service.

  • Page 299: Speed Sensor

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM Faults Menu What it means: If the voltage seen by the controller coming out of the MCOR is not within specified limits, this fault occurs. What to do: Replace MCOR. NOTE: Newer controllers may, infrequently, read voltages above or below limits and give a false fault. SPEED SENSOR If the speed controller does not detect pulses from the speed sensor while the controller outputs power (greater than 75% armature PWM) to the motor, a speed sensor fault is detected.

  • Page 300: Fld (Field) Missing

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Faults Menu DIAGNOSTICS: EXCEL SYSTEM FLD (FIELD) MISSING If the speed controller is operating at a duty cycle of greater than 90% (almost full speed) and the field current is less than 3 amps, a field missing fault is detected by the speed controller. CAUTION •...

  • Page 301: Motor Stall

    The max password tries fault is declared when the incorrect password fault has been declared several times. In the event that the max password tries fault is indicated, the speed controller must be removed and shipped to Club Car before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 23-4. See also Password Tries (IQDM-P Only) on page 16-6.

  • Page 302: Clearing Fault History

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Functions Menu DIAGNOSTICS: EXCEL SYSTEM fault history menu, the trained technician should attempt to determine when and where the fault has occurred. For example, if the motor stall fault is present in the fault history, the trained technician may be able to determine the location on the course where an operator has held the vehicle on a hill by using the accelerator pedal.

  • Page 303: Write Settings To Controller

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM Functions Menu 10. With the controller settings stored in the memory of the handset, the handset can be used to transfer all of the desired speed controller settings to any Excel System vehicle or group of Excel System vehicles. See Speed Controller Cloning –...

  • Page 304: Reset All Settings

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Functions Menu DIAGNOSTICS: EXCEL SYSTEM Scroll to the functions menu and select. Select settings. Select write settings to controller. Press + on the change value button to confirm the operation. The handset will display an “executing...” message for the next few seconds while the controller settings are being stored in the handset’s memory (Figure 16-4, Page 16-15).

  • Page 305: Information

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM Information Press + on the change value button to confirm the operation. The handset will display an “executing...” message for the next few seconds while the controller settings are being stored in the handset’s memory (Figure 16-4, Page 16-15). When the handset is finished resetting the speed controller settings, a confirmation message is displayed (Figure 16-7, Page 16-16).

  • Page 306: Programmer Setup

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Programmer Setup DIAGNOSTICS: EXCEL SYSTEM PROGRAMMER SETUP The programmer setup menu selection allows the user to set the LCD display contrast, records the fault history of the handset, and displays information pertaining to the handset. PROGRAM This menu allows the user to adjust the contrast on the display screen.

  • Page 307: Iqdm And Iqdm-P Handset Troubleshooting

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM IQDM and IQDM-P Handset Troubleshooting IQDM AND IQDM-P HANDSET TROUBLESHOOTING In the event that the handset does not function as described in this manual, the following troubleshooting guide should be studied and the referenced test procedures should be performed to troubleshoot the handset. TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES...

  • Page 308: Test Procedures

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Test Procedures DIAGNOSTICS: EXCEL SYSTEM TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Disconnect the IQDM cord from the vehicle. Handset malfunction Wait a few seconds and reconnect the handset to the vehicle Vehicle batteries – loose terminals or corrosion See Section 18 –...
  • Page 309 IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM Test Procedures Place the black (–) probe on each of the pins, one at a time, on the other plug of the adaptor. The multimeter should indicate continuity on only one pin. If any other reading is obtained, the adaptor must be replaced.
  • Page 310 IQ DISPLAY MODULE (IQDM) AND IQDM-P Test Procedures DIAGNOSTICS: EXCEL SYSTEM 4.3.1. Disconnect the square four-pin connector (3) from the speed controller. 4.3.2. Connect the handset cord to the handset. 4.3.3. Connect the other end of the handset cord (without the adapter) (4) to the four-pin connector of the speed controller (2) (Figure 16-9, Page 16-22).

  • Page 311: Section 17 - Electrical Components

    SECTION 17 – ELECTRICAL COMPONENTS DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. KEY SWITCH See General Warnings on page 1-1. TESTING THE KEY SWITCH See the appropriate troubleshooting section for the type of electrical system used in the vehicle. See IQ System Troubleshooting –...

  • Page 312: Battery Warning Light

    Battery Warning Light ELECTRICAL COMPONENTS 3.2. Position the instrument panel (2) on the dash assembly. Make sure tabs on upper edge properly engage with the corresponding slots on the dash assembly. Ensure that there are no wires exposed or pinched during positioning.

  • Page 313: Battery Warning Light Installation

    ELECTRICAL COMPONENTS Forward/Reverse Rocker Switch BATTERY WARNING LIGHT INSTALLATION Install in reverse order of removal. Place the Tow/Run switch in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-3. Figure 17-3 Battery Warning Light FORWARD/REVERSE ROCKER SWITCH See General Warnings on page 1-1.

  • Page 314: Forward/Reverse Rocker Switch Installation

    Forward/Reverse Rocker Switch ELECTRICAL COMPONENTS Figure 17-4 Forward/Reverse Rocker Switch FORWARD/REVERSE ROCKER SWITCH INSTALLATION Route the three wires through bezel. Connect the blue (4), orange (5) and brown (6) wires to the rocker switch (3), exactly as shown in (Figure 17-4, Page 17-4). Orient the rocker switch (3) so the terminals are towards the front of the housing (1).

  • Page 315: Electronics Module Cover

    ELECTRICAL COMPONENTS Electronics Module Cover ELECTRONICS MODULE COVER See General Warnings on page 1-1. The electronics module cover needs to be removed to gain access to the speed controller, Tow/Run switch, and onboard computer. ELECTRONICS MODULE COVER REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-3.

  • Page 316: Tow/Run Switch

    Tow/Run Switch ELECTRICAL COMPONENTS Figure 17-5 Access and Remove Electronics Module Cover TOW/RUN SWITCH See General Warnings on page 1-1. TESTING THE TOW/RUN SWITCH See Test Procedure 6 – Tow/Run Switch on page 14-19. TOW/RUN SWITCH REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-3.

  • Page 317: Throttle Position Sensor (Tps)

    ELECTRICAL COMPONENTS Throttle Position Sensor (TPS) Return electronics module to its original location and secure with bolt (11) (Figure 17-8, Page 17-11). Tighten bolt to 40 in-lb (4.5 N·m). Place the Tow/Run switch in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-3.

  • Page 318: Motor Controller Output Regulator (Mcor)

    Motor Controller Output Regulator (MCOR) ELECTRICAL COMPONENTS MOTOR CONTROLLER OUTPUT REGULATOR (MCOR) See General Warnings on page 1-1. TESTING THE MCOR For IQ System see Test Procedure 4 – MCOR Voltage on page 12-16 and Test Procedure 8 – Key Switch and MCOR Limit Switch Circuit on page 12-21.

  • Page 319: Reverse Buzzer Installation

    ELECTRICAL COMPONENTS Electronics Module Disconnect the 18-gauge pink and orange/white wires from reverse buzzer. Remove the two screws from the reverse buzzer. Remove the reverse buzzer from the dash panel. REVERSE BUZZER INSTALLATION Install the reverse buzzer in the reverse order of removal. Pink wire must be connected to the positive terminal. Tighten screws to 4 in-lb (0.45 N·m).

  • Page 320: Electronics Module Installation

    Electronics Module ELECTRICAL COMPONENTS Disconnect the 16-pin connector, 4-pin connector, and spade connectors from the controller. Remove the three self-tapping screws (10) that hold the controller to the component mounting plate (14) and remove the controller from the vehicle. Remove two nuts (3) on top of the solenoid (5) posts and remove the wires from the posts. Disconnect the spade connectors on the front of the solenoid.
  • Page 321 ELECTRICAL COMPONENTS Electronics Module Figure 17-8 Electronics Module Removal 2009-2011 Electric Precedent Maintenance and Service Manual Page 17-11...

  • Page 322: Speed Controller

    Speed Controller ELECTRICAL COMPONENTS SPEED CONTROLLER See General Warnings on page 1-1. TESTING THE SOLID STATE SPEED CONTROLLER See Test Procedure 5 – A1 and A2 Motor Voltage on page 14-18. SPEED CONTROLLER REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-3.

  • Page 323: Solenoid

    ELECTRICAL COMPONENTS Solenoid 8.6. Select Information, Software Version and verify the value is 13 or higher. If not, contact a Club Car Technical Representative. 8.7. Place the Tow/Run switch in the TOW position for 30 seconds. Then return it to RUN.

  • Page 324: Onboard Computer (Obc)

    Onboard Computer (OBC) ELECTRICAL COMPONENTS Place the Tow/Run switch in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-3. ONBOARD COMPUTER (OBC) See General Warnings on page 1-1. TESTING THE ONBOARD COMPUTER See Test Procedure 2 –...

  • Page 325: Charger Receptacle

    ELECTRICAL COMPONENTS Charger Receptacle CHARGER RECEPTACLE See General Warnings on page 1-1. The charger cord, plug, and receptacle are wear items and should be inspected daily. Visually inspect them for cracks, loose connections, and frayed wiring; they must be replaced when worn or damaged. If charger plug or receptacle show signs of corrosion or the plug is difficult to insert or remove, the receptacle contacts and plug terminals should be cleaned with a good electrical contact cleaner or lightly sprayed with WD-40 ®...

  • Page 326: Charger Receptacle Installation

    Headlight Adjustment ELECTRICAL COMPONENTS Disconnect the gray wire from the OBC. Remove the three screws (1) that secure the charger receptacle (2) to the bucket. CHARGER RECEPTACLE INSTALLATION Insert the wires through the hole in the bucket (Figure 17-9, Page 17-15). Insert receptacle (2) into bucket.
  • Page 327 ELECTRICAL COMPONENTS Headlight Adjustment Figure 17-10 Headlight Aiming 2009-2011 Electric Precedent Maintenance and Service Manual Page 17-17...

  • Page 328: Ferrite Beads - Ce Mark Vehicles

    Ferrite Beads – CE Mark Vehicles ELECTRICAL COMPONENTS FERRITE BEADS – CE MARK VEHICLES NOTE: CE Mark IQ System vehicles are no longer offered starting model year 2011. These beads bring the IQ System vehicle into compliance with EMC requirements for use in the European Union. 1.

  • Page 329: Section 18 - Batteries

    SECTION 18 – BATTERIES DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.

  • Page 330: Battery Troubleshooting Chart

    Battery Troubleshooting Chart BATTERIES BATTERY TROUBLESHOOTING CHART V ehicle not operating to expectation. Fully Charge Batteries. Battery Charger T Reading of 6 amps or more. Reading below 6 amps and on-charge voltage above 56 volts. Check electrical system and charger for problems.

  • Page 331: Battery Testing - 12 Volt

    BATTERIES Battery Testing – 12 Volt BATTERY TESTING – 12 VOLT See General Warnings on page 1-1. Four tests have been developed to help diagnose problems with batteries that have not performed as expected. Because each test becomes progressively more detailed and time-consuming, begin with the first test and follow through with the other tests until the problem has been identified as outlined in the Battery Troubleshooting Chart (Figure 18-1, Page 18-2).
  • Page 332 Battery Testing – 12 Volt BATTERIES CAUTION • Do not allow battery acid from battery caps or hydrometer to drip onto the front or rear body of the vehicle. Battery acid will cause permanent damage. Wash immediately. Remove the vent cap. Using a battery thermometer (CC P/N 1011767), record electrolyte temperature of the no.
  • Page 333 BATTERIES Battery Testing – 12 Volt Interpreting the Results of the Hydrometer Test The approximate state of charge can be determined from the following table: APPROXIMATE SPECIFIC GRAVITY (TEMPERATURE CORRECTED) STATE OF CHARGE 1.250-1.280 100% 1.220-1.240 1.190-1.210 1.160-1.180 If the difference between the cells is 0.020 or more, the low cell should be suspected. It may require a catch-up charge or it may be a weak cell.

  • Page 334: Discharge Test

    Battery Testing – 12 Volt BATTERIES DISCHARGE TEST If the previous tests have failed to identify the problem, conduct a discharge test. The discharge test comes closest to simulating actual vehicle operating conditions by continuously drawing current from the batteries until voltage drops to 42.0 volts.
  • Page 335 BATTERIES Battery Testing – 12 Volt Interpreting Discharge Test Results If discharge time is 60 minutes or higher, the problem is not with the batteries. If discharge times are low (less than 60 minutes), replace batteries below 10.05 volts. BATTERY VOLTAGES BATTERY CONDITION 10.50 V 10.50 V...

  • Page 336: Battery Troubleshooting Examples

    Battery Testing – 12 Volt BATTERIES BATTERY TROUBLESHOOTING EXAMPLES The following information represents a few examples of troubleshooting battery problems. Example 1 Vehicle no. 68 was suspected of having a bad battery due to its performance. As a result, the battery charger test was performed.

  • Page 337: Battery Testing - 8 Volt

    BATTERIES Battery Testing – 8 Volt BATTERY TESTING – 8 VOLT See General Warnings on page 1-1. Four tests have been developed to help diagnose problems with batteries that have not performed as expected. Because each test becomes progressively more detailed and time-consuming, begin with the first test and follow through with the other tests until the problem has been identified as outlined in the Battery Troubleshooting Chart (Figure 18-1, Page 18-2).
  • Page 338 Battery Testing – 8 Volt BATTERIES CAUTION • Do not allow battery acid from battery caps or hydrometer to drip onto the front or rear body of the vehicle. Battery acid will cause permanent damage. Wash immediately. Remove the vent cap. Using a battery thermometer (P/N 1011767), record electrolyte temperature of the no. 2 cell.
  • Page 339 BATTERIES Battery Testing – 8 Volt Interpreting the Results of the Hydrometer Test The approximate state of charge can be determined from the following table: APPROXIMATE SPECIFIC GRAVITY (TEMPERATURE CORRECTED) STATE OF CHARGE 1.250-1.280 100% 1.220-1.240 1.190-1.210 1.160-1.180 If the difference between the cells is 0.020 or more, the low cell should be suspected. It may require a catch-up charge or it may be a weak cell.

  • Page 340: Discharge Test

    Battery Testing – 8 Volt BATTERIES DISCHARGE TEST If the previous tests have failed to identify the problem, conduct a discharge test. The discharge test comes closest to simulating actual vehicle operating conditions by continuously drawing current from the batteries until voltage drops to 42.0 volts.
  • Page 341 BATTERIES Battery Testing – 8 Volt Interpreting Discharge Test Results If discharge time is 60 minutes or higher, the problem is not with the batteries. If discharge times are low (less than 60 minutes), replace batteries below 6.7 volts. BATTERY VOLTAGES BATTERY CONDITION 7.00 7.00...

  • Page 342: Battery Troubleshooting Examples

    Battery Testing – 8 Volt BATTERIES BATTERY TROUBLESHOOTING EXAMPLES The following information represents a few examples of troubleshooting battery problems. Example 1 Vehicle no. 68 was suspected of having a bad battery due to its performance. As a result, the battery charger test was performed.

  • Page 343: Battery Replacement

    BATTERIES Battery Replacement BATTERY REPLACEMENT See General Warnings on page 1-1. WARNING • To prevent electrolyte leakage from the battery vents, batteries must be kept in an upright position. Tipping a battery beyond a 45° angle in any direction can allow a small amount of electrolyte to leak out the vent hole.

  • Page 344: Battery Care

    This process creates a finished product free of minerals, having left all the impurities in the original water sample. Club Car, along with our battery manufacturers, highly recommends that distilled water be used in electric vehicle batteries.

  • Page 345: Battery Care - Vehicles Equipped With The Single-Point Watering System

    BATTERIES Battery Care ALLOWABLE CONTENT (PARTS IMPURITY EFFECTS OF IMPURITY PER MILLION) Suspended matter Trace Total solids 100.0 Organic and volatile matter 50.0 Corrosion of positive plates Ammonia Slight self-discharge of both plates Self-discharge, reduces life, lower Antimony on-charge voltage Arsenic Self-discharge, can form poisonous gas Calcium...

  • Page 346: Battery Care - Vehicles Without The Single-Point Watering System

    Battery Care BATTERIES WARNING • If battery wire terminals are damaged or corroded, replace or clean them as necessary. Failure to do so may cause them to overheat during operation and could result in fire, property damage, or personal injury. After use, charge the batteries.

  • Page 347: Self-Discharge

    BATTERIES Battery Care CAUTION • Do not overfill the batteries. NOTE: A battery watering gun or bottle is available at many auto parts dealers. The battery hold-downs should be tight enough so that the batteries do not move while the vehicle is in motion, but not so tight as to crack or buckle the battery case.

  • Page 348: Vibration Damage

    Battery Charger – High Frequency BATTERIES CAUTION 1. Level Indicator 2. Cap 3. Plates Electrolyte level at least 1/2 inch (13 MM) above plates or to level indicator. Figure 18-8 Battery Electrolyte Level Add water only after charging unless the electrolyte is below the level of the plates. If the electrolyte level is below the level of the plates, add just enough water to cover the plates and then charge the batteries.

  • Page 349: Battery Charger - Ferroresonant

    WARNING • Only trained technicians should repair or service the charger. Contact your nearest Club Car distributor/dealer. • Each charger should have its own dedicated 15 or 20 ampere separately protected (circuit breaker or fuse) single phase branch circuit, in accordance with all applicable electrical codes for the location.

  • Page 350: Charging Batteries

    Battery Charger – Ferroresonant BATTERIES WARNING • Do not allow clothing, blankets, or other material to cover the charger. • Do not allow the charger to operate for more than 30 minutes at 19 or more amperes. • Install surge arrestors on incoming AC power lines. Surge arrestors will help protect electrical components in the charger and on the vehicle from all but direct or close lightning strikes.
  • Page 351 When inserting the DC plug, align the raised guide on the plug with the guide slot in the receptacle and push straight in slowly. Club Car battery chargers interact with the vehicle’s onboard computer. The computer records the amount of energy consumed during vehicle use. While the charger is plugged in, the vehicle’s control circuit is locked out, preventing operation of the vehicle as well as the possibility of consequent damage to the charger and the vehicle.

  • Page 352: Plug And Receptacle

    Batteries should be put on charge even if they have been used for only a short period (10 minutes). The charger is automatic and will turn off when batteries are fully charged. If the charger does not seem to be operating properly, or if the batteries seem weak, contact your local Club Car distributor/dealer. PLUG AND RECEPTACLE The charger cord, plug, and receptacle are wear items and should be inspected daily.

  • Page 353: Fleet Rotation

    BATTERIES Single Point Watering System (SPWS) FLEET ROTATION Rotate vehicle usage. It is very hard on batteries if the last vehicles in at night are the first ones out in the morning. Spread the workload evenly, giving all vehicles the same amount of use. This will keep your fleet in balance and will not overwork certain sets of batteries.

  • Page 354: Watering Batteries With The Spws

    Single Point Watering System (SPWS) BATTERIES WATERING BATTERIES WITH THE SPWS Checking the Water Flow Rate Connect the water hose with the built-in screen filter (2) to the water faucet (1) (Figure 18-11, Page 18-26). See following CAUTION. CAUTION • Make sure the screen filter is clean. •...
  • Page 355 BATTERIES Single Point Watering System (SPWS) Figure 18-13 Dust Cap Figure 18-14 Connecting Hose-end Assembly to Battery Fill Connector The red flow indicator balls should swirl, indicating that the batteries are being filled. See following CAUTION. CAUTION • If at any time water overflows from the batteries, immediately stop the refill process, disconnect the pressure regulator from the battery fill coupling, and call for service.

  • Page 356: Battery Storage

    Battery Storage BATTERIES BATTERY STORAGE See General Warnings on page 1-1. When storing batteries during the off-season or when maintaining a replacement stock, follow these guidelines: Keep the batteries clean and free of corrosion. See Battery Care on page 18-16. Batteries that are in vehicles for winter storage should be left disconnected in the vehicles if the batteries are not going to be connected to a charger.

  • Page 357: Section 19 - Battery Charger

    SECTION 19 – BATTERY CHARGER Refer to the appropriate battery charger maintenance and service manual. 2009-2011 Electric Precedent Maintenance and Service Manual Page 19-1...

  • Page 359: Section 20 - Motor (Model Ej4-4001 And Ej8-4001A)

    The vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. The shunt-wound motor is designed for use in IQ and Excel System vehicles only. Club Car recommends that motors requiring major repair be sent to a qualified motor repair shop; however, there are many relatively simple tasks that can be performed by a technician with general knowledge and experience in electric motor repair.

  • Page 360: External Motor Testing

    External Motor Testing MOTOR (MODEL EJ4-4001 AND EJ8-4001A) EXTERNAL MOTOR TESTING The following tests can be performed without disassembling the motor using a multimeter or continuity tester. NOTE: Tag the motor wires for identification before disconnecting. Scrape a small amount of paint from motor housing (ground) and use this location when testing motor terminals to electrical ground.

  • Page 361: Motor

    MOTOR (MODEL EJ4-4001 AND EJ8-4001A) Motor Disconnect wires from the A1 and A2 terminals on the motor using two wrenches to prevent posts from turning. Set a multimeter to 200 ohms and place the red (+) probe on the A1 terminal and black (–) probe on the A2 terminal.
  • Page 362 Motor MOTOR (MODEL EJ4-4001 AND EJ8-4001A) Figure 20-1 Lift Vehicle with Floor Jack Figure 20-2 Vehicle Supported on Jack Stands Remove both rear wheels. Remove the nut, cup washer, and bushing from the bottom side of the shock absorber. Compress the shock absorber (pushing upwards) to move it out of the way (Figure 20-3, Page 20-4).

  • Page 363: Motor Disassembly

    MOTOR (MODEL EJ4-4001 AND EJ8-4001A) Motor Figure 20-4 Speed Sensor Magnet Figure 20-5 End Cap MOTOR DISASSEMBLY Before beginning disassembly, place match marks on the motor end cap and motor frame. Remove speed sensor and magnet. 2.1. Remove the two screws (25) that secure the speed sensor (10) to the end cap (11) (Figure 20-15, Page 20-11).
  • Page 364 Motor MOTOR (MODEL EJ4-4001 AND EJ8-4001A) CAUTION • Ensure that there is sufficient thread engagement of the end cap bolts before proceeding. Performing the procedure without having adequate thread engagement could damage the motor frame, end cap, or end cap bolts. 5.2.

  • Page 365: Motor Component Testing And Inspection

    MOTOR (MODEL EJ4-4001 AND EJ8-4001A) Motor Component Testing and Inspection Figure 20-8 Armature Removal Figure 20-9 A1 and A2 Terminals Figure 20-10 Brush Rigging Figure 20-11 Bearing Retaining Ring MOTOR COMPONENT TESTING AND INSPECTION See General Warnings on page 1-1. ARMATURE INSPECTION AND TESTING Remove the motor from the vehicle.
  • Page 366 Motor Component Testing and Inspection MOTOR (MODEL EJ4-4001 AND EJ8-4001A) • Flared armature windings • Damaged armature core laminations • Worn, burned or glazed commutators • Dirty or oily commutators • Raised commutator bars • Worn armature bearing or shaft A dirty or oily commutator should be cleaned and wiped dry.

  • Page 367: Motor Frame And Field Windings Inspection

    MOTOR (MODEL EJ4-4001 AND EJ8-4001A) Motor Component Testing and Inspection MOTOR FRAME AND FIELD WINDINGS INSPECTION Remove the motor from the vehicle. See Motor Removal on page 20-3. Remove the and cap and armature by performing steps 1 through 7 of Motor Disassembly on page 20-5. Burned or scorched insulation on the field windings indicates the motor has overheated due to overloads or grounded or shorted coil windings.
  • Page 368 Motor Component Testing and Inspection MOTOR (MODEL EJ4-4001 AND EJ8-4001A) Bearing Inspection NOTE: Replacement of the end cap bearing is highly-recommended if the end cap is removed from the motor. The following procedure is provided as a guideline for determining general bearing failure. Remove the motor from the vehicle.
  • Page 369 MOTOR (MODEL EJ4-4001 AND EJ8-4001A) Motor Component Testing and Inspection Items 19, 20, 21, and 22: Used only on EJ4–4001 motor Figure 20-15 Motor 2009-2011 Electric Precedent Maintenance and Service Manual Page 20-11...

  • Page 370: Reconditioning The Motor

    Reconditioning the Motor MOTOR (MODEL EJ4-4001 AND EJ8-4001A) RECONDITIONING THE MOTOR See General Warnings on page 1-1. Motor reconditioning must be performed by a qualified motor repair technician. The use of proper tools and procedures is absolutely essential for successful motor reconditioning. MOTOR SPECIFICATIONS Any rework must be performed by a qualified technician.
  • Page 371 MOTOR (MODEL EJ4-4001 AND EJ8-4001A) Motor Assembly Figure 20-16 Brush Rigging Figure 20-17 Retracted Brushes Figure 20-18 Armature Installation Figure 20-19 Brush Setting With the brushes retracted, use an arbor press to press the armature shaft into the end cap bearing (Figure 20-18, Page 20-13).

  • Page 372: Motor Installation

    Motor Installation MOTOR (MODEL EJ4-4001 AND EJ8-4001A) MOTOR INSTALLATION See General Warnings on page 1-1. Clean the transaxle input shaft. 1.1. Spray the input shaft thoroughly with CRC ® Brakleen™ or equivalent brake cleaner degreaser. 1.2. Wipe input shaft with a clean cloth. 1.3.
  • Page 373 MOTOR (MODEL EJ4-4001 AND EJ8-4001A) Motor Installation When the motor is pushed onto the input shaft, the motor housing will not bottom out against the transaxle housing (Figure 20-15, Page 20-11). There will be approximately 1/16 inch (1.6 mm) gap between the motor adapter ring and transaxle housing as shown (Figure 20-23, Page 20-15).
  • Page 374 Motor Installation MOTOR (MODEL EJ4-4001 AND EJ8-4001A) 4.10.Connect the three-pin speed sensor wire to the vehicle wire harness. If using a chain hoist, lower the vehicle and guide the leaf springs into the shackles. If using a floor jack, raise the transaxle until the leaf springs can be guided into the shackles.

  • Page 375: Section 21 - Transaxle (Type G)

    SECTION 21 – TRANSAXLE (TYPE G) DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. LUBRICATION See General Warnings on page 1-1. There are two plugs located on the lower half of the transaxle housing. The upper plug (21) (as viewed when the vehicle is on a level surface) is used as a lubricant level indicator (Figure 21-5, Page 21-3).
  • Page 376 Axle Bearing and Shaft TRANSAXLE (TYPE G) CAUTION • Do not scar or damage the inside surfaces of the tube when removing the oil seal and adapter ring. A damaged tube might have to be replaced. NOTE: Do not discard the adapter ring. If the adapter ring is lost or damaged, the axle tube will have to be replaced. Varying rear axle configurations have been installed on vehicles.
  • Page 377 TRANSAXLE (TYPE G) Axle Bearing and Shaft Figure 21-5 Transaxle – Type G 2009-2011 Electric Precedent Maintenance and Service Manual Page 21-3...

  • Page 378: Axle Bearing

    Axle Bearing and Shaft TRANSAXLE (TYPE G) Axle Shaft and Oil Seal Installation If previously removed, install a new oil seal. 1.1. Clean seal seat in the adapter ring (39) (Figure 21-3, Page 21-2). 1.2. Place a new seal (15) in the adapter ring with the seal lip facing toward the adapter ring lip (Figure 21-3, Page 21-2).

  • Page 379: Transaxle

    TRANSAXLE (TYPE G) Transaxle TRANSAXLE See General Warnings on page 1-1. TRANSAXLE REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-3. Place chocks at the front wheels and slightly loosen lug nuts on both rear wheels. See WARNING “Lift only one end...”...
  • Page 380 Transaxle TRANSAXLE (TYPE G) CAUTION • Do not position fingers under motor when sliding motor off of the input shaft. Fingers may get pinched when motor disengages. Figure 21-8 Disconnect Shocks Figure 21-9 Shackles 11. Carefully remove the motor from the transaxle. Slide the motor away from the transaxle until the motor spline becomes disengaged from the input shaft, then lift motor out.
  • Page 381 TRANSAXLE (TYPE G) Transaxle 1. Precedent 2. Villager 4 Figure 21-10 Leaf Springs Figure 21-11 Motor Mounting Bolts Figure 21-12 Motor Positioning Bolt – EJ4–4001 and 5BC59JBS6390 Motors Only 2009-2011 Electric Precedent Maintenance and Service Manual Page 21-7...

  • Page 382: Transaxle Disassembly, Inspection, And Assembly

    Transaxle Disassembly, Inspection, and Assembly TRANSAXLE (TYPE G) TRANSAXLE DISASSEMBLY, INSPECTION, AND ASSEMBLY See General Warnings on page 1-1. TRANSAXLE DISASSEMBLY AND INSPECTION To detach axle tubes (14 and 35) from the transaxle housing, remove the bolts (8) (Figure 21-5, Page 21-3). Remove 11 bolts (24) that hold housing together.
  • Page 383 TRANSAXLE (TYPE G) Transaxle Disassembly, Inspection, and Assembly Disassemble the differential gear case: 8.1. Remove the hex bolts (33) and the ring gear (32) from the differential case (Figure 21-5, Page 21-3). 8.2. Remove the ring gear. 8.3. Separate the differential gear case housing. If necessary, install two of the hex bolts (removed previously in step 8.1.) into the differential gear unit and, while holding the unit slightly above the work area, lightly tap the bolt heads (Figure 21-14, Page 21-9).

  • Page 384: Transaxle Assembly

    Transaxle Disassembly, Inspection, and Assembly TRANSAXLE (TYPE G) TRANSAXLE ASSEMBLY CAUTION • Do not press against the bearing outer race. • The housing and all parts must be wiped clean and dry before reassembly. If bearings (13) were removed during disassembly, install new bearings using an arbor press (Figure 21-5, Page 21-3).

  • Page 385: Transaxle Installation

    TRANSAXLE (TYPE G) Transaxle Installation WARNING • Be sure retaining ring is properly seated in its groove. If ring is not properly installed, the axle assembly will separate from the transaxle and damage the axle assembly and other components. Loss of vehicle control could result in severe personal injury or death.
  • Page 386 Transaxle Installation TRANSAXLE (TYPE G) WARNING • Make sure that the vehicle operates in the reverse direction when the Forward/Reverse switch is in the REVERSE position. The reverse buzzer will sound as a warning when the Forward/Reverse switch is in REVERSE. •...

  • Page 387: Section 22 - Iq Display Module Programmer (Iqdm-P): Iq System

    SECTION 22 – IQ DISPLAY MODULE PROGRAMMER (IQDM-P): IQ SYSTEM DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. NOTE: For information pertaining to the introductory display, menu navigation, and monitor, faults and function menus, see IQ Display Module (IQDM) and IQDM-P Diagnostics: IQ System on page 15-1.

  • Page 388: Program Menu

    IQ DISPLAY MODULE PROGRAMMER Program Menu (IQDM-P): IQ SYSTEM PROGRAM MENU The program menu can be accessed by pressing the right arrow on the navigation button when the square beside program is blinking (Figure 22-2, Page 22-2). When the program menu is active, use the up or down arrows on the navigation button to go to the desired item in the program menu.

  • Page 389: Speed Setting

    ANSI Z130.1 – American National Standard for Golf Cars – Safety and Performance Specifications because it is capable of speeds in excess of 15 mph (24.1 km/h). For more information on this feature, contact your local Club Car distributor or dealer. 2009-2011 Electric Precedent Maintenance and Service Manual...

  • Page 390: Slow Pedal Up

    IQ DISPLAY MODULE PROGRAMMER Program Menu (IQDM-P): IQ SYSTEM SLOW PEDAL UP slow pedal up is an option that toggles either on or off. With the slow pedal up parameter turned off, downhill speed with the pedal up will be maintained at 11.3 mph (18.2 kph). Turned on, this parameter maintains pedal up, downhill speed at 10.4 mph (16.8 kph).

  • Page 391: Section 23 - Iq Display Module Programmer (Iqdm-P): Excel System

    SECTION 23 – IQ DISPLAY MODULE PROGRAMMER (IQDM-P): EXCEL SYSTEM DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. NOTE: For information pertaining to the introductory display, menu navigation, and monitor, faults and function menus, see IQ Display Module (IQDM) and IQDM-P Diagnostics: Excel System on page 16-1.

  • Page 392: Program Menu

    IQ DISPLAY MODULE PROGRAMMER Program Menu (IQDM-P): EXCEL SYSTEM PROGRAM MENU The program menu can be accessed by pressing the right arrow on the navigation button when the square beside program is blinking (Figure 23-3, Page 23-2). When the program menu is active, use the up or down arrows on the navigation button to go to the desired item in the program menu.

  • Page 393: Speed Setting

    IQ DISPLAY MODULE PROGRAMMER (IQDM-P): EXCEL SYSTEM Program Menu SPEED SETTING The vehicle’s top speed can be changed by selecting values 1 through 3 (Figure 23-4, Page 23-2). If a value of 4 is displayed for the speed setting, a special access code has been entered to place the vehicle in “private speed mode.” A speed setting of 4 cannot be selected with the speed setting menu item.

  • Page 394: S3 Fwd Speed

    ANSI Z130.1 – American National Standard for Golf Cars – Safety and Performance Specifications because it is capable of speeds in excess of 15 mph (24.1 km/h). For more information on this feature, contact your local Club Car distributor or dealer. VEHICLE S/N Six digit number programmed by vehicle manufacturer.
  • Page 395 INDEX installation ............4-3 removal .............. 4-3 accelerator pedal see also repair, front and rear body ...... 4-3 installation ............5-6 body, rear removal .............. 5-6 removal .............. 4-9 access panel ..........4-11, 4-15 see also repair, front and rear body ..... 4-9, 4-13 armature, motor brake pedal see motor, armature ..........
  • Page 396 INDEX communication display module (CDM) high pedal detect ......11-7, 12-7, 13-2, 14-2 function codes....11-35, 12-39, 13-35, 14-38 retrieving data from .........11-36, 12-40, 13-36, 14-39 troubleshooting ....11-38, 12-40, 13-38, 14-40 inspection connector, 16-pin front wheel free play .......... 7-18 see test procedures .........11-21, motor 12-23, 13-21, 14-22...
  • Page 397 INDEX Menu Navigation..........15-2 periodic lubrication schedule ......10-6 Monitor Menu ..........15-4 periodic service schedule........10-3 Programmer Setup........15-17 motor ......... 11-1, 12-1, 13-2, 14-2, 20-1 Reset All Settings......... 15-15 armature System Faults..........15-7 ground test ............ 20-8 Test Procedures........... 15-19 inspection............
  • Page 398 INDEX removal ............5-1, 5-3 solenoid periodic lubrication schedule ......... 10-6 installation ............17-13 periodic service schedule ........10-3 removal ............17-13 testing ......11-32, 12-35, 13-32, 14-35 solenoid activating coil testing ......11-15, 12-16, 13-15, 14-15 specifications rack and pinion ............7-4 vehicle..............
  • Page 399 INDEX removal ............9-4 installation ............8-3 suspension, rear (two-passenger) removal .............. 8-2 leaf spring repair..............8-2 installation ............9-3 Tow/Run switch ......11-7, 12-7, 13-2, 14-2 removal ............9-2 installation ............17-6 sweater basket ............4-9 removal ............17-6 testing ......
  • Page 401 5. If you are reviewing a Kit Instruction, were all indicated parts included in your kit? Yes / No Your Comments and Suggestions: Please send a copy of this page to: Fax: (706) 228-2662 or Thank You! E-mail: Tech_Pubs@clubcar.com Club Car’s Technical Publications Department 2009-2011 Electric Precedent Maintenance and Service Manual...

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