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Electric Precedent 2008
Club Car Electric Precedent 2008 Manuals
Manuals and User Guides for Club Car Electric Precedent 2008. We have
1
Club Car Electric Precedent 2008 manual available for free PDF download: Maintenance And Service Manual
Club Car Electric Precedent 2008 Maintenance And Service Manual (344 pages)
Brand:
Club Car
| Category:
Golf Cars
| Size: 22.63 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
Serial Number Identification
21
Safety Committee
22
Storage
22
Preparing the Electric Vehicle for Extended Off-Season Storage
23
Returning the Stored Electric Vehicle to Service
23
Section 4 - Body and Trim
25
Cleaning the Vehicle
25
Seat
25
Front and Rear Body Repair
26
Stress Lines or Streaks
26
Minor Impact Damage/Deformations
26
Minor Scratches and Surface Blemishes
26
Gouges, Punctures, Tears, Large Scratches, and Abrasions
27
Front Body
27
Front Body Removal
27
Front Body Installation
27
Front Bumper
29
Instrument Panel
29
Instrument Panel Removal - Early Model Year
29
Instrument Panel Installation - Early Model Year
30
Instrument Panel Removal - Late Model Year
30
Instrument Panel Installation - Late Model Year
31
Floor Mat and Retainers
32
Floor Mat Retainer Removal
32
Floor Mat Retainer Installation
32
Kick Plate and Charger Receptacle Bezel
33
Kick Plate and Charger Receptacle Bezel Removal
33
Kick Plate and Charger Receptacle Bezel Installation
33
Rear Body - Two-Passenger Vehicles
34
Universal Accessory Mounting
34
Backrest and Structural Accessory Module (SAM)
34
Rear Body Components (Two-Passenger)
35
Rear Body - Four-Passenger Vehicles
38
Seat Backs
38
Seat Support
38
Foot Deck
39
Rear Body Components (Four-Passenger)
40
Canopy - Two-Passenger
41
Two-Passenger Canopy Removal
41
Two-Passenger Canopy Installation
43
Canopy - Four-Passenger
43
Four-Passenger Canopy Removal
43
Four-Passenger Canopy Installation
44
Section 5 - Accelerator and Brake Pedal Group
47
Pedal Group
47
Pedal Group Removal
47
Mcor
49
Debris Shields
49
Brake Return Spring
49
Pawl Assembly
49
Accelerator Return Spring
50
Pedal Group Installation
52
Section 6 - Wheel Brake Assemblies
53
General Information
53
Brake Shoe Removal
53
Brake Assembly Cleaning
57
Brake Shoe Installation
59
Brake Cable Equalizer Adjustment
62
Brake Cluster Removal and Installation
63
Brake Cluster Removal
63
Brake Cluster Installation
63
Brake Cable Removal and Installation
65
Brake Cable Removal
65
Brake Cable Installation
66
Section 7 - Steering and Front Suspension
69
General Information
69
Steering Wheel
69
Steering Wheel Removal
69
Steering Wheel Installation
70
Steering Column
70
Steering Column Removal
70
Steering Column Installation
71
Rack and Pinion
72
Rack and Pinion Removal
72
Rack and Pinion Disassembly
73
Rack and Pinion Assembly
75
Rack and Pinion Installation
76
Front Suspension
78
Lubrication
78
Wheel Alignment
78
Front Suspension Components
80
Tie Rod End Removal
80
Tie Rod Installation
80
Leaf Spring Removal
81
Leaf Spring Installation
81
Kingpin and Steering Spindle Removal
81
Kingpin and Steering Spindle Installation
81
Control Arm Removal
82
Control Arm Installation
82
Shock Absorber Removal
82
Shock Absorber Installation
82
Front Wheel Bearings and Hubs
85
Front Wheel Free Play Inspection
85
Front Hub Removal
85
Hub Installation
85
Section 8 - Wheels and Tires
87
General Information
87
Wheels
87
Wheel Removal
87
Wheel Installation
87
Tires
88
Tire Removal
88
Tire Repair
88
Tire Installation
89
Section 9 - Rear Suspension
91
General Information
91
Shock Absorbers
91
Shock Absorber Removal and Inspection
91
Shock Absorber Installation
91
Leaf Springs (Two-Passenger Vehicles)
92
Leaf Spring Removal (Two-Passenger Vehicles)
92
Leaf Spring Installation (Two-Passenger Vehicles)
93
Leaf Springs (Four-Passenger Vehicles)
94
Leaf Spring Removal (Four-Passenger Vehicles)
94
Leaf Spring Installation (Four-Passenger Vehicles)
95
Section 10 - Periodic Maintenance
97
General Warning
97
General Information
99
Periodic Service Schedule
99
Periodic Lubrication Schedule
101
Section 11 - Iq System Troubleshooting
103
General Information
103
Wiring Diagrams
104
Troubleshooting
109
Troubleshooting the Vehicle with the IQDM
109
Troubleshooting Guide 1
110
Troubleshooting Guide 2
113
Test Procedures
115
Communication Display Module (CDM)
140
Using the CDM to Retrieve Data from the Onboard Computer
141
CDM Troubleshooting Guide
141
Section 12 - Excel System Troubleshooting
143
General Information
143
Wiring Diagrams
144
Troubleshooting
149
Troubleshooting the Vehicle with the IQDM
149
Troubleshooting Guide 1
149
Troubleshooting Guide 2
153
Test Procedures
155
Communication Display Module (CDM)
180
Using the CDM to Retrieve Data from the Onboard Computer
181
CDM Troubleshooting Guide
181
Section 13 - Iq Display Module (Iqdm) and Iqdm-Pdiagnostics: Iq System
183
Plugging the Handset into the Vehicle
183
Introductory Display
184
Menu Navigation
184
Program (IQDM-P Only)
185
Monitor
185
Faults
186
Functions
186
Information
186
Programmer Setup
186
Monitor Menu
186
Throttle
186
Batt Voltage
187
Heatsink
187
Arm Current
187
Field Current
187
Arm PWM
187
Field PWM
187
Speed Pulses
187
Foot Input
187
Forward Input
188
Reverse Input
188
Main Cont
188
Key Input
188
Password Tries (IQDM-P Only)
188
10.3 Transaxle
188
20+ Speed
188
Faults Menu
189
System Faults
189
HW Failsafe
191
KEY SWITCH SRO (Static Return to Off)
191
Throttle Fault 1
192
Speed Sensor
192
Main Welded
192
Main Driver on
192
Main Driver off
192
High Speed Walkaway
192
Main Coil FAULT
192
Field Missing
193
Hpd
193
Proc/Wiring
193
Overvoltage
193
Low Battery Voltage
193
Thermal Cutback
193
Motor Stall
193
Main Dropout
193
Open Armature
194
Incorrect Password (IQDM-P Only)
194
Max Password Tries (IQDM-P Only)
194
Fault History
194
Clearing Fault History
194
Functions Menu
195
Get Settings from Controller
195
Write Settings to Controller
196
Reset All Settings
197
Information
198
Model Number
198
Serial Number
198
MFG Date
198
Software Version
198
Programmer Setup
198
Program
198
Faults
199
Information
199
IQDM and IQDM-P Handset Troubleshooting
200
Test Procedures
201
Section 14 - Iq Display Module (Iqdm) and Iqdm-Pdiagnostics: Excel System
205
Plugging the Handset into the Vehicle
205
Introductory Display
206
Menu Navigation
206
Program (IQDM-P Only)
207
Monitor
207
Faults
207
Functions
208
Information
208
Programmer Setup
208
Monitor Menu
208
Speed
208
Throttle
209
Batt aux Voltage
209
Temperature
209
Arm Current
209
Field Current
209
Armature PWM
209
Field PWM
209
Brake Volts in
209
Speed Pulses
210
Foot Input
210
Key Input
210
Forward Input
210
Reverse Input
210
Charger Inhibit
210
Main Cont Driver
210
Password Tries (IQDM-P Only)
211
Odometer
211
Vehicle Speeds (IQDM-P Only)
211
Pedal Counters
211
Fault Counters
211
Fault Count Odometers
211
Faults Menu
212
System Faults
212
HW Failsafe
214
Throttle Fault
214
Speed Sensor
215
Main Welded
215
Main Driver on
215
Main Driver off
215
Main Coil Open
215
Field Missing
215
Hpd
215
Overvoltage
215
Low Battery Voltage
216
Thermal Cutback
216
Motor Stall
216
Main Dropout (1 or 2)
216
Incorrect Password (IQDM-P Only)
216
Max Password Tries (IQDM-P Only)
216
Fault History
216
Clearing Fault History
217
Functions Menu
217
Get Settings from Controller
217
Write Settings to Controller
218
Reset All Settings
219
Information
220
Model Number
220
Serial Number
220
MFG Date
220
Software Version
220
Programmer Setup
220
Program
220
Faults
221
Information
221
IQDM and IQDM-P Handset Troubleshooting
222
Test Procedures
223
Section 15 - Electrical Components
227
Key Switch
227
Testing the Key Switch
227
Key Switch Removal
227
Key Switch Installation
227
Battery Warning Light
228
Testing the Battery Warning Light
228
Battery Warning Light Removal
228
Battery Warning Light Installation
229
Forward/Reverse Rocker Switch
229
Testing the Forward/Reverse Rocker Switch
229
Forward/Reverse Rocker Switch Removal
229
Forward/Reverse Rocker Switch Installation
230
Electronics Module Cover - Style a Battery Configuration
231
Electronics Module Cover Removal
231
Electronics Module Cover Installation
231
Electronics Module Cover - Styleb and C Battery Configurations
232
Electronics Module Cover Removal
232
Electronics Module Cover Installation
232
Tow/Run Switch - Style a Battery Configuration
233
Testing the Tow/Run Switch
233
Tow/Run Switch Removal
233
Tow/Run Switch Installation
234
Tow/Run Switch - Style B and C Battery Configurations
234
Testing the Tow/Run Switch
234
Tow/Run Switch Removal
234
Tow/Run Switch Installation
235
Motor Controller Output Regulator (MCOR)
235
Testing the MCOR
235
MCOR Removal
235
MCOR Installation
236
Reverse Buzzer
236
Testing the Reverse Buzzer
236
Reverse Buzzer Removal
236
Reverse Buzzer Installation
237
Electronics Module - Style a Battery Configuration
237
Electronics Module Removal
237
Electronics Module Installation
238
Electronics Module - Style B and C Battery Configurations
240
Electronics Module Removal
240
Electronics Module Installation
240
Speed Controller - Style a Battery Configuration
243
Testing the Solid State Speed Controller
243
Speed Controller Removal
243
Speed Controller Installation
243
Speed Controller - Style B and C Battery Configurations
244
Testing the Solid State Speed Controller
244
Speed Controller Removal
244
Speed Controller Installation
244
Solenoid - Style a Battery Configuration
245
Testing the Solenoid
245
Solenoid Removal
245
Solenoid Installation
245
Solenoid - Style B and C Battery Configurations
246
Testing the Solenoid
246
Solenoid Removal
246
Solenoid Installation
246
Onboard Computer (OBC) - Style a Battery Configuration
247
Testing the Onboard Computer
247
Onboard Computer Removal
247
Onboard Computer Installation
247
Onboard Computer (OBC) - Style B and C Battery Configurations
248
Testing the Onboard Computer
248
Onboard Computer Removal
248
Onboard Computer Installation
248
Charger Receptacle
249
Testing the Charger Receptacle
249
Charger Receptacle Inspection
249
Charger Receptacle Removal
249
Charger Receptacle Installation
250
Headlight Adjustment
251
Aiming the Headlight Beam
251
Ferrite Beads - CE Mark Vehicles
252
Section 16 - Batteries
253
General Information
253
Battery Troubleshooting Chart
254
Battery Testing - 12 Volt
255
Battery Charger Test
255
On-Charge Voltage Test
255
Hydrometer Test
255
Discharge Test
258
Battery Troubleshooting Examples
260
Battery Testing - 8 Volt
261
Battery Charger Test
261
On-Charge Voltage Test
261
Hydrometer Test
261
Discharge Test
264
Battery Troubleshooting Examples
266
Battery Replacement
267
Battery Care
268
Battery Care - Vehicles Equipped with the Single-Point Watering System
268
Battery Care - Vehicles Without the Single-Point Watering System
269
Self-Discharge
270
Electrolyte Level
270
Mineral Content
271
Vibration Damage
271
Battery Charger
271
Charging Batteries
272
Plug and Receptacle
273
Charger Shuts off after 16 Hours
273
Deep-Discharge
273
Early Excessive Discharging
274
Incoming AC Service
274
Fleet Rotation
274
Numbering Vehicles and Chargers
274
Single Point Watering System (SPWS)
274
Initial Maintenance of the SPWS
275
Watering Batteries with the SPWS
275
Battery Storage
277
Charging a Battery Pack that Has Low Voltage
277
Section 17 - Battery Charger
279
Section 18 - Motor (Model 5Bc59Jbs6390)
281
General Information
281
Motor Identification
281
External Motor Testing
281
Motor
283
Motor Removal
283
Motor Component Testing and Inspection
285
Armature
285
Field Windings Inspection
286
Motor Components
286
Bearing Inspection
287
Bearing Removal
289
Bearing Installation
289
Speed Sensor Magnet Inspection
289
Speed Sensor Magnet Removal
289
Speed Sensor Magnet Installation
289
Reconditioning the Motor
289
Motor Specifications
290
Motor Assembly
290
Motor Installation
292
Motor Speed Sensor
296
Testing the Motor Speed Sensor
296
Motor Speed Sensor Removal
296
Motor Speed Sensor Installation
296
Section 19 - Motor (Model Ej4-4001)
299
General Information
299
Motor Identification
299
External Motor Testing
299
Motor
300
Motor Removal
300
Motor Disassembly
302
Motor Component Testing and Inspection
304
Armature Inspection and Testing
304
Motor Frame and Field Windings Inspection
306
Motor Brush, Spring, and Terminal Insulator Inspection
306
Reconditioning the Motor
309
Motor Specifications
309
Motor Assembly
309
Motor Installation
311
Section 20 - Transaxle (Type G)
315
Lubrication
315
Axle Bearing and Shaft
315
Axle Shaft
315
Axle Bearing
318
Transaxle
319
Transaxle Removal
319
Transaxle Disassembly, Inspection, and Assembly
322
Transaxle Disassembly and Inspection
322
Transaxle Assembly
324
Transaxle Installation
325
Section 21 - Iq Display Module Programmer (Iqdm-P): Iq System
327
Plugging the Handset into the Vehicle
327
Program Menu
327
Speed Setting
328
Fast Accel
329
Pedal up Mode
329
Speed Cal
329
Code A, Code B, and Code C
329
Slow Pedal up
329
KSI SRO Enable
330
M2 Max Speed
330
Section 22 - Iq Display Module Programmer (Iqdm-P): Excel System
331
Plugging the Handset into the Vehicle
331
Program Menu
332
Speed Setting
333
Fast Accel
333
Pedal up Mode
333
Speed Cal
333
S3 FWD Speed
334
Code A, Code B, and Code C
334
Vehicle S/N
334
Vehicle Decal
334
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