Club Car 2009-20011 Electric Precedent Manuals

Manuals and User Guides for Club Car 2009-20011 Electric Precedent. We have 1 Club Car 2009-20011 Electric Precedent manual available for free PDF download: Maintenance And Service Manual

Club Car 2009-20011 Electric Precedent Maintenance And Service Manual

Club Car 2009-20011 Electric Precedent Maintenance And Service Manual (404 pages)

IQ System and Excel System Vehicles

Brand: Club Car | Category: Offroad Vehicle | Size: 27.68 MB

Table of Contents

Table of Contents
5
Section 1 - Safety
15
- General Warnings
  15
Section 2 - Vehicle Specifications
19
Section 3 - General Information
21
Section 4 - Body and Trim
25
- Cleaning the Vehicle
  25
  - Seat
    25
- Front and Rear Body Repair
  26
- Front Body
  27
  - Front Body Removal
    27
  - Front Body Installation
    27
- Front Bumper
  29
- Instrument Panel
  30
  - Instrument Panel Removal
    30
  - Instrument Panel Installation
    30
- Floor Mat and Retainers
  31
  - Floor Mat Retainer Removal
    31
  - Floor Mat Retainer Installation
    31
- Kick Plate and Charger Receptacle Bezel
  32
  - Kick Plate and Charger Receptacle Bezel Removal
    32
  - Kick Plate and Charger Receptacle Bezel Installation
    32
- Rear Body - Two-Passenger Vehicles
  33
- Rear Body - Four-Passenger Vehicles
  37
  - Seat Backs
    37
  - Seat Support
    37
  - Foot Deck
    38
  - Rear Body Components (Four-Passenger)
    39
- Canopy - Two-Passenger
  40
  - Two-Passenger Canopy Removal
    40
  - Two-Passenger Canopy Installation
    42
- Canopy - Four-Passenger
  42
  - Four-Passenger Canopy Removal
    42
  - Four-Passenger Canopy Installation
    43
- Canopy (Monsoon Version) - Four-Passenger
  45
  - Monsoon Canopy Removal
    45
  - Monsoon Canopy Installation
    45
Section 5 - Accelerator and Brake Pedal Group
49
- Pedal Group - Throttle Position Sensor
  49
  - Pedal Group Removal
    49
  - Throttle Position Sensor (TPS)
    51
  - Pedal Group Installation
    51
- Pedal Group - MCOR
  51
  - Pedal Group Removal
    51
  - Pedal Group Installation
    52
  - Mcor
    52
- Debris Shields
  53
- Accelerator Pedal Removal
  54
- Accelerator Pedal Installation
  54
- Brake Pedal Removal
  54
- Brake Pedal Installation
  54
Section 6 - Wheel Brake Assemblies
57
- General Information
  57
- Brake Shoe Removal
  57
- Brake Assembly Cleaning
  61
- Brake Shoe Installation
  63
- Brake Cable Equalizer Adjustment
  66
- Brake Cluster Removal and Installation
  67
  - Brake Cluster Removal
    67
  - Brake Cluster Installation
    67
- Brake Cable Removal and Installation
  69
  - Brake Cable Removal
    69
  - Brake Cable Installation
    70
Section 7 - Steering and Front Suspension
73
- General Information
  73
- Steering Wheel
  73
  - Steering Wheel Removal
    73
  - Steering Wheel Installation
    74
- Steering Column
  74
  - Steering Column Removal
    74
  - Steering Column Installation
    75
- Rack and Pinion
  76
  - Rack and Pinion Inspection
    76
  - Rack and Pinion Removal
    77
  - Rack and Pinion Disassembly
    77
  - Rack and Pinion Assembly
    80
  - Rack and Pinion Installation
    81
- Front Suspension
  83
  - Lubrication
    83
  - Wheel Alignment
    83
- Front Suspension Components
  85
  - Tie Rod End Removal
    85
  - Tie Rod Installation
    85
  - Leaf Spring Removal
    86
  - Leaf Spring Installation
    86
  - Kingpin and Steering Spindle Removal
    86
  - Kingpin and Steering Spindle Installation
    86
  - Control Arm Removal
    87
  - Control Arm Installation
    87
  - Shock Absorber Removal
    87
  - Shock Absorber Installation
    87
- Front Wheel Bearings and Hubs
  90
  - Front Wheel Free Play Inspection
    90
  - Front Hub Removal
    90
  - Hub Installation
    90
Section 8 - Wheels and Tires
93
- General Information
  93
- Wheels
  93
  - Wheel Removal
    93
  - Wheel Installation
    93
- Tires
  94
  - Tire Removal
    94
  - Tire Repair
    94
  - Tire Installation
    95
Section 9 - Rear Suspension
97
Section 10 - Periodic Maintenance
103
- General Warning
  103
- General Information
  105
- Periodic Service Schedule
  105
- Periodic Lubrication Schedule
  108
Section 11 - Iq System Troubleshooting - Tps
109
- General Information
  109
- Wiring Diagrams
  110
- Troubleshooting
  115
  - Troubleshooting the Vehicle with the IQDM
    115
  - Troubleshooting Guide 1
    116
  - Troubleshooting Guide 2
    119
- Test Procedures
  121
- Battery Warning Light
  143
- Communication Display Module (CDM)
  143
  - Using the CDM to Retrieve Data from the Onboard Computer
    144
- CDM Troubleshooting Guide
  146
Section 12 - Iq System Troubleshooting - Mcor
147
- General Information
  147
- Wiring Diagrams
  148
- Troubleshooting
  153
  - Troubleshooting the Vehicle with the IQDM
    153
  - Troubleshooting Guide 1
    154
  - Troubleshooting Guide 2
    157
- Test Procedures
  159
- Battery Warning Light
  184
- Communication Display Module (CDM)
  185
  - Using the CDM to Retrieve Data from the Onboard Computer
    186
- CDM Troubleshooting Guide
  186
Section 13 - Excel System Troubleshooting - Tps
189
- General Information
  189
  - Differences between the Excel and IQ Systems
    189
  - Features
    190
- Wiring Diagrams
  191
- Troubleshooting
  196
  - Troubleshooting the Vehicle with the IQDM
    196
  - Troubleshooting Guide 1
    196
  - Troubleshooting Guide 2
    199
- Test Procedures
  201
- Battery Warning Light
  223
- Communication Display Module (CDM)
  223
  - Using the CDM to Retrieve Data from the Onboard Computer
    224
- CDM Troubleshooting Guide
  226
Section 14 - Excel System Troubleshooting - Mcor
227
- General Information
  227
  - Differences between the Excel and IQ Systems
    227
  - Features
    228
- Wiring Diagrams
  229
- Troubleshooting
  234
  - Troubleshooting the Vehicle with the IQDM
    234
  - Troubleshooting Guide 1
    234
  - Troubleshooting Guide 2
    237
- Test Procedures
  239
- Battery Warning Light
  264
- Communication Display Module (CDM)
  264
  - Using the CDM to Retrieve Data from the Onboard Computer
    265
- CDM Troubleshooting Guide
  266
Section 15 - Iq Display Module (Iqdm) and Iqdm-Pdiagnostics: Iq System
267
- Plugging the Handset into the Vehicle
  267
- Introductory Display
  267
- Menu Navigation
  268
  - Program (IQDM-P Only)
    269
  - Monitor
    269
  - Faults
    270
  - Functions
    270
  - Information
    270
  - Programmer Setup
    270
- Monitor Menu
  270
  - Throttle
    270
  - Batt Voltage
    271
  - Heatsink
    271
  - Arm Current
    271
  - Field Current
    271
  - Arm PWM
    271
  - Field PWM
    271
  - Speed Pulses
    271
  - Foot Input
    271
  - Forward Input
    272
  - Reverse Input
    272
  - Main Cont
    272
  - Key Input
    272
  - Password Tries (IQDM-P Only)
    272
  - 10.3 Transaxle
    272
  - 20+ Speed
    272
- Faults Menu
  273
  - System Faults
    273
  - HW Failsafe
    274
  - KEY SWITCH SRO (Static Return to Off)
    275
  - Throttle Fault 1
    276
  - Speed Sensor
    276
  - Main Welded
    276
  - Main Driver on
    276
  - Main Driver off
    276
  - High Speed Walkaway
    276
  - Main Coil FAULT
    276
  - Field Missing
    277
  - Hpd
    277
  - Proc/Wiring
    277
  - Overvoltage
    277
  - Low Battery Voltage
    277
  - Thermal Cutback
    277
  - Motor Stall
    277
  - Main Dropout
    277
  - Open Armature
    278
  - Incorrect Password (IQDM-P Only)
    278
  - Max Password Tries (IQDM-P Only)
    278
  - Fault History
    278
  - Clearing Fault History
    278
- Functions Menu
  279
  - Get Settings from Controller
    279
  - Write Settings to Controller
    280
  - Reset All Settings
    281
- Information
  282
  - Model Number
    282
  - Serial Number
    282
  - MFG Date
    282
  - Software Version
    282
- Programmer Setup
  283
  - Program
    283
  - Faults
    283
  - Information
    283
- IQDM and IQDM-P Handset Troubleshooting
  284
- Test Procedures
  285
Section 16 - Iq Display Module (Iqdm) and Iqdm-Pdiagnostics: Excel System
289
- Plugging the Handset into the Vehicle
  289
- Introductory Display
  290
- Menu Navigation
  291
  - Program (IQDM-P Only)
    291
  - Monitor
    291
  - Faults
    291
  - Functions
    291
  - Information
    292
  - Programmer Setup
    292
- Monitor Menu
  292
  - Speed
    292
  - Throttle
    292
  - Batt Aux Voltage
    293
  - Temperature (same as Heatsink in IQ System)
    293
  - Arm Current
    293
  - Field Current
    293
  - Armature PWM
    293
  - Field PWM
    293
  - Brake Volts in
    293
  - Speed Pulses
    293
  - Foot Input
    294
  - Key Input
    294
  - Forward Input
    294
  - Reverse Input
    294
  - Charger Inhibit
    294
  - Main Cont Driver
    294
  - Password Tries (IQDM-P Only)
    294
  - Odometer
    295
  - Vehicle Speeds (IQDM-P Only)
    295
  - Pedal Counters
    295
  - Fault Counters
    295
  - Fault Count Odometers
    295
  - Neg IA 250
    295
  - Neg IA 300
    295
- Faults Menu
  296
  - System Faults
    296
  - Controller Fault
    297
  - HW Failsafe
    298
  - Throttle Fault
    298
  - Speed Sensor
    299
  - Main Welded
    299
  - Main Driver on
    299
  - Main Driver off
    299
  - Main Coil Open
    299
  - FLD (Field) Missing
    300
  - Hpd
    300
  - Overvoltage
    300
  - Low Battery Voltage (Undervoltage)
    300
  - Thermal Cutback
    300
  - Motor Stall
    301
  - Main Dropout (1 or 2)
    301
  - Current Sense Fault
    301
  - Incorrect Password (IQDM-P Only)
    301
  - Max Password Tries (IQDM-P Only)
    301
  - Fault History
    301
  - Clearing Fault History
    302
- Functions Menu
  302
  - Get Settings from Controller
    302
  - Write Settings to Controller
    303
  - Reset All Settings
    304
- Information
  305
  - Model Number
    305
  - Serial Number
    305
  - MFG Date
    305
  - Software Version
    305
- Programmer Setup
  306
  - Program
    306
  - Faults
    306
  - Information
    306
- IQDM and IQDM-P Handset Troubleshooting
  307
- Test Procedures
  308
Section 17 - Electrical Components
311
- Key Switch
  311
  - Testing the Key Switch
    311
  - Key Switch Removal
    311
  - Key Switch Installation
    311
- Battery Warning Light
  312
- Forward/Reverse Rocker Switch
  313
- Electronics Module Cover
  315
  - Electronics Module Cover Removal
    315
  - Electronics Module Cover Installation
    315
- Tow/Run Switch
  316
  - Testing the Tow/Run Switch
    316
  - Tow/Run Switch Removal
    316
  - Tow/Run Switch Installation
    316
- Throttle Position Sensor (TPS)
  317
  - Testing the Throttle Position Sensor
    317
  - Throttle Position Sensor Replacement
    317
- Motor Controller Output Regulator (MCOR)
  318
  - Testing the MCOR
    318
  - MCOR Removal
    318
  - MCOR Installation
    318
- Reverse Buzzer
  318
  - Testing the Reverse Buzzer
    318
  - Reverse Buzzer Removal
    318
  - Reverse Buzzer Installation
    319
- Electronics Module
  319
  - Electronics Module Removal
    319
  - Electronics Module Installation
    320
- Speed Controller
  322
- Solenoid
  323
  - Testing the Solenoid
    323
  - Solenoid Removal
    323
  - Solenoid Installation
    323
- Onboard Computer (OBC)
  324
  - Testing the Onboard Computer
    324
  - Onboard Computer Removal
    324
  - Onboard Computer Installation
    324
- Charger Receptacle
  325
  - Testing the Charger Receptacle
    325
  - Charger Receptacle Inspection
    325
  - Charger Receptacle Removal
    325
  - Charger Receptacle Installation
    326
- Headlight Adjustment
  326
  - Aiming the Headlight Beam
    326
- Ferrite Beads - CE Mark Vehicles
  328
Section 18 - Batteries
329
- General Information
  329
- Battery Troubleshooting Chart
  330
- Battery Testing - 12 Volt
  331
  - Battery Charger Test
    331
  - On-Charge Voltage Test
    331
  - Hydrometer Test
    331
  - Discharge Test
    334
  - Battery Troubleshooting Examples
    336
- Battery Testing - 8 Volt
  337
  - Battery Charger Test
    337
  - On-Charge Voltage Test
    337
  - Hydrometer Test
    337
  - Discharge Test
    340
  - Battery Troubleshooting Examples
    342
- Battery Replacement
  343
- Battery Care
  344
- Battery Charger - High Frequency
  348
- Battery Charger - Ferroresonant
  349
  - Charging Batteries
    350
  - Plug and Receptacle
    352
  - Charger Shuts off after 16 Hours
    352
  - Deep-Discharge
    352
  - Early Excessive Discharging
    352
  - Incoming AC Service
    352
  - Fleet Rotation
    353
  - Numbering Vehicles and Chargers
    353
- Single Point Watering System (SPWS)
  353
  - Initial Maintenance of the SPWS
    353
  - Watering Batteries with the SPWS
    354
- Battery Storage
  356
- Charging a Battery Pack that Has Low Voltage
  356
Section 19 - Battery Charger
357
Section 20 - Motor (Model Ej4-4001 and Ej8-4001A)
359
- General Information
  359
- Motor Identification
  359
- External Motor Testing
  360
- Motor
  361
  - Motor Removal
    361
  - Motor Disassembly
    363
- Motor Component Testing and Inspection
  365
- Reconditioning the Motor
  370
  - Motor Specifications
    370
- Motor Assembly
  370
- Motor Installation
  372
Section 21 - Transaxle (Type G)
375
- Lubrication
  375
- Axle Bearing and Shaft
  375
  - Axle Shaft
    375
  - Axle Bearing
    378
- Transaxle
  379
  - Transaxle Removal
    379
- Transaxle Disassembly, Inspection, and Assembly
  382
  - Transaxle Disassembly and Inspection
    382
  - Transaxle Assembly
    384
- Transaxle Installation
  385
Section 22 - Iq Display Module Programmer (Iqdm-P): Iq System
387
- Plugging the Handset into the Vehicle
  387
- Program Menu
  388
  - Speed Setting
    389
  - Fast Accel
    389
  - Pedal up Mode
    389
  - Speed Cal
    389
  - Code A, Code B, and Code C
    389
  - Slow Pedal up
    390
  - KSI SRO Enable
    390
  - M2 Max Speed
    390
Section 23 - Iq Display Module Programmer (Iqdm-P): Excel System
391
- Plugging the Handset into the Vehicle
  391
- Program Menu
  392
  - Speed Setting
    393
  - Fast Accel
    393
  - Pedal up Mode
    393
  - Speed Cal
    393
  - S3 FWD Speed
    394
  - Code A, Code B, and Code C
    394

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