Page 1 2008-2011 IQ System Maintenance and Service Manual Supplement DS Villager 4, Carryall 1, Turf 1 IQ System Electric Vehicles Manual Number 103373106 Edition Code 1007D1210C...
Page 3 If it appears that a service question is not answered in this supplement, you may write to us at: Club Car, LLC, P.O. Box 204658; Augusta, Georgia 30917-4658, USA, Attention: Technical Services, or contact a Club Car Technical Service Representative at (706) 863-3000, ext.
Page 4 NOTE: This supplement represents the most current information at the time of publication. Club Car, LLC is continually working to further improve its vehicles and other products. These improvements may affect servicing procedures.
Page 5: Table Of Contents
CONTENTS SECTION 10 – PERIODIC MAINTENANCE General Warning ..........................10-1 Disabling The Vehicle ........................10-2 Disconnecting The Batteries ......................10-3 Connecting The Batteries ......................10-3 General Information .......................... 10-4 Periodic Service Schedule ........................ 10-4 Periodic Lubrication Schedule ......................10-6 SECTION 11 – ELECTRICAL SYSTEM AND TESTING General Information ..........................
Page 6 Programmer Setup ........................... 12-14 Program ............................12-14 Faults ............................12-14 Information ........................... 12-15 IQDM and IQDM-P Handset Troubleshooting .................. 12-15 Test Procedures ..........................12-17 Index of Test Procedures ......................12-17 SECTION 13 – ELECTRICAL COMPONENTS Key Switch ............................13-1 Forward/Reverse Rocker Switch ...................... 13-3 Tow/Run Switch ..........................
Page 7 Battery Troubleshooting Chart ......................14-6 Battery Testing – 8 Volt ........................14-7 Battery Charger Test ........................14-7 On-Charge Voltage Test ....................... 14-7 Hydrometer Test ........................... 14-7 Discharge Test ..........................14-9 Battery Troubleshooting Examples ....................14-11 Battery Testing – 12 Volt ........................14-12 Battery Charger Test ........................
Page 8 SECTION 16B – MOTOR (MODELS EJ4-4001 AND EJ8-4001A) General Information ......................... 16b-1 Motor Identification ........................... 16b-1 External Motor Testing ........................16b-1 Motor ..............................16b-3 Motor Removal ..........................16b-3 Motor Disassembly ........................16b-5 Motor Component Testing and Inspection ..................16b-7 Armature Inspection and Testing ....................16b-7 Motor Frame and Field Windings Inspection ................
Page 9: 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 ser- viced. 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 vehi- cle.
Page 10: Disabling The Vehicle
PERIODIC MAINTENANCE General Warning ý WARNING • To avoid unintentionally starting the vehicle, place Tow/Run switch in the TOW position, then disconnect the batteries as shown (Figure 10-1, Page 10-2) and (Figure 10-2, Page 10-2). • After disconnecting the batteries, wait 90 seconds for the controller capacitors to discharge. •...
Page 11: Disconnecting The Batteries
PERIODIC MAINTENANCE General Warning (–) Figure 10-3 Battery Cable Removal – Turf 1/Carryall 1 6x8-Volt Battery Configuration (Viewed from driver side of vehicle) 1. Place TOW/RUN Switch in TOW before disconnecting or connecting battery cables. 2. Remove negative battery cable. 3.
Page 12: General Information
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 ser- vice. PERIODIC SERVICE SCHEDULE ý...
Page 13 PERIODIC MAINTENANCE Periodic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Daily service by owner See Pre-Operation and Daily Safety Pre-Operation and Daily Safety Checklist Checklist in the appropriate Owner’s Manual See Performance Inspection in the Performance Inspection appropriate Owner’s Manual Charge batteries (after each daily use Batteries only).
Page 14: Periodic Lubrication Schedule
PERIODIC MAINTENANCE Periodic Lubrication Schedule PERIODIC LUBRICATION SCHEDULE See General Warning on page 10-1. PERIODIC LUBRICATION SCHEDULE LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Semiannually by owner Brake pedal shaft bearings Dry Moly Lube (CC P/N 1012151) or trained technician (every 50 hours of operation or 100 rounds of golf) Brake linkage and pivots...
Page 15: Section 11 - Electrical System And Testing
SECTION 11 – ELECTRICAL SYSTEM AND TESTING ý DANGER • See General Warning, Section 10, Page 10-1. ý WARNING • See General Warning, Section 10, Page 10-1. GENERAL INFORMATION The IQ System vehicle uses a 48-volt electrical system that is powered by deep-cycle lead-acid batteries and includes an onboard computer.
Page 16: Wiring Diagrams
(PIN 4) GRN/WHT : TO S. O. C (PIN 5) LT BLUE : TO OBC "CONTROLLER LOCKOUT" 000412-001 Figure 11-1 Wiring Diagram with Pin 9 Diode – DS Villager 4 Page 11-2 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement...
Page 17 6_BLK(W66) ON-BOARD 6_WHT(W62) COMPUTER 18_LHT_BLU(W10) 6_BLK(W55) 3 PIN 6_GRN(W64) CONNECTOR 18_BLK_WHT(W09) 18_LT_GREEN(W02) 18_RED(W19) 18_GRN_WHT(W30) 10_BLK(W49) 6_BLK(W55) 000412-001 Figure 11-2 Wiring Diagram with Pin 9 Diode – DS Villager 4 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement Page 11-3...
Page 18 ELECTRICAL SYSTEM AND TESTING Wiring Diagrams 18_BRN_WHT (W08) 16_BLK_WHT (W42) 6_WHT (W62) 10_BLU (W63) 6_GRN (W64) 10_BLK (W49) 103689601 Figure 11-3 Wiring Diagram without Pin 9 Diode – DS Villager 4 Page 11-4 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement...
Page 19 ELECTRICAL SYSTEM AND TESTING Wiring Diagrams 6_BLK 6_BLK 6_BLK 103689601 Figure 11-4 Wiring Diagram without Pin 9 Diode – DS Villager 4 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement Page 11-5...
Page 20 ELECTRICAL SYSTEM AND TESTING Wiring Diagrams 000606-001 Figure 11-5 Wiring Diagram with Pin 9 Diode – Turf 1 and Carryall 1 Vehicles Page 11-6 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement...
Page 21 ELECTRICAL SYSTEM AND TESTING Wiring Diagrams 000606-001 Figure 11-6 Wiring Diagram with Pin 9 Diode – Turf 1 and Carryall 1 Vehicles 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement Page 11-7...
Page 22 ELECTRICAL SYSTEM AND TESTING Wiring Diagrams 18_ORG (W35) 18_BRN_WHT (W08) 16_BLK_WHT (W42) 10_BLU (W63) 6_GRN (W64) 10_BLK (W49) 103689701 Figure 11-7 Wiring Diagram without Pin 9 Diode – Turf 1 and Carryall 1 Vehicles Page 11-8 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement...
Page 23 ELECTRICAL SYSTEM AND TESTING Wiring Diagrams 103689701 Figure 11-8 Wiring Diagram without Pin 9 Diode – Turf 1 and Carryall 1 Vehicles 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement Page 11-9...
Page 24: Troubleshooting
TROUBLESHOOTING THE VEHICLE WITH THE IQDM Club Car recommends the use of the IQDM handset for troubleshooting vehicles equipped with the IQ elec- trical system. Troubleshooting Guide 1 is to be used in conjunction with the IQDM handset. See Section 12 –...
Page 25: Troubleshooting Guide 1
ELECTRICAL SYSTEM AND TESTING Troubleshooting TROUBLESHOOTING GUIDE 1 The following troubleshooting guide is intended for use with an IQDM handset. For IQDM operating instruc- tions, See Section 12 – IQ Display Module (IQDM) Series 2 and IQDM-P Diagnostics. See following NOTE.
Page 26 ELECTRICAL SYSTEM AND TESTING Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Test Menu – MAIN CONT (solenoid) Disconnect the batteries and discharge does not indicate ON when the the controller. See Disconnecting The Speed controller logic malfunction solenoid should be activated. Batteries on page 10-3.
Page 27 ELECTRICAL SYSTEM AND TESTING Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Diagnostic Menu – FIELD MISSING Loose or disconnected motor field coil fault code wires at motor or speed controller or Repair and/or connect the field coil wires broken wire Failure of the motor field windings Section 16 –...
Page 28: Troubleshooting Guide 2
ELECTRICAL SYSTEM AND TESTING Troubleshooting TROUBLESHOOTING GUIDE 2 TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Vehicle does not operate Batteries discharged Charge batteries Check vehicle wiring. See Wiring Improper or poor battery connections Diagrams on page 11-2. Battery charger is connected to the Disconnect the battery charger from the vehicle –...
Page 29 ELECTRICAL SYSTEM AND TESTING Troubleshooting TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Vehicle runs slowly Test Procedure 13 – Motor Speed Sensor Speed sensor disconnected or failed on page 11-36 To change the programmed top speed of Incorrect speed setting the vehicle, an IQDM-P handset must be used Check vehicle wiring.
Page 30: Test Procedures
ELECTRICAL SYSTEM AND TESTING Troubleshooting TEST PROCEDURES Using the following procedures, the entire IQ electrical system can be tested without major disassembly of the vehicle. See following WARNING. ý WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured.
Page 31 ELECTRICAL SYSTEM AND TESTING Troubleshooting TEST PROCEDURE 1 – BATTERIES / VOLTAGE CHECK See General Warning, Section 10, Page 10-1. NOTE: The batteries must be properly maintained and fully charged in order to perform the following test procedures. Battery maintenance procedures, including watering information and allowable min- eral content, can be found in Section 14 of this manual.
Page 32 ELECTRICAL SYSTEM AND TESTING Troubleshooting WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Figure 11-11 Battery Voltage Check – IQ System DS Villager 4 4x12-Volt Configuration TEST PROCEDURE 2 – ONBOARD COMPUTER SOLENOID LOCKOUT CIRCUIT See General Warning, Section 10, Page 10-1. The solenoid lockout circuit disables the vehicle when the battery charger is plugged into the vehicle.
Page 33 ELECTRICAL SYSTEM AND TESTING Troubleshooting 6.2. Set a multimeter to 200 volts DC. Place the black (–) probe on the battery no. 6 negative post and place the red (+) probe (with insulation-piercing probe) on the red 18-gauge wire (harness side of six-pin connector).
Page 34 ELECTRICAL SYSTEM AND TESTING Troubleshooting NOTE: The key switch should be placed in the OFF position and left in the OFF position for the duration of this test. 2. Connect the IQDM to the vehicle. 3. Access the Test menu and select THROTTLE % by using the SCROLL DISPLAY buttons. 4.
Page 35 ELECTRICAL SYSTEM AND TESTING Troubleshooting white wire with an insulation-piercing probe. 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.
Page 36 ELECTRICAL SYSTEM AND TESTING Troubleshooting 5. If the IQDM display screen begins to work after the vehicle has been driven, turn the key switch to the OFF position and proceed to step 6; otherwise, perform the following procedure, Tow/Run Switch Test without the IQDM Handset.
Page 37 ELECTRICAL SYSTEM AND TESTING Troubleshooting TEST PROCEDURE 8 – KEY SWITCH AND MCOR LIMIT SWITCH CIRCUIT See General Warning, Section 10, Page 10-1. Key Switch and MCOR Limit Switch Circuit Test with the IQDM Handset 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 crossmember between the spring mount and side stringer, just forward of each rear wheel.
Page 38 ELECTRICAL SYSTEM AND TESTING Troubleshooting Place the black (–) probe on the other key switch terminal. 4.3. With the key switch in the OFF position, the multimeter should indicate that continuity is not present. 4.4. With the key switch in the ON position, the multimeter should indicate that continuity is present. 4.5.
Page 39 ELECTRICAL SYSTEM AND TESTING Troubleshooting TEST PROCEDURE 9 – 16-PIN CONNECTOR See General Warning, Section 10, Page 10-1. 1. Disconnect the batteries and discharge the controller. See Disconnecting The Batteries on page 10-3. 2. 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 40 ELECTRICAL SYSTEM AND TESTING Troubleshooting 1. Disconnect the batteries and discharge the controller. See Disconnecting The Batteries on page 10-3. 2. 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 between the spring mount and side stringer, just forward of each rear wheel.
Page 41 ELECTRICAL SYSTEM AND TESTING Troubleshooting Test Procedure 9B – Pin 5 See General Warning, Section 10, Page 10-1. Pin 5 in the 16-pin connector provides a connection point for the solenoid lockout circuit from the onboard computer to the speed controller. 1.
Page 42 ELECTRICAL SYSTEM AND TESTING Troubleshooting SPEED CONTROLLER WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV SETTING (READING WITH OBC POWERED-UP AND BATTERY CHARGER DISCONNECTED) Figure 11-15 Pin 5 Test Test Procedure 9C – Pin 6 See General Warning, Section 10, Page 10-1. Pin 6 in the 16-pin connector provides a connection point for the MCOR limit switch to the speed controller.
Page 43 ELECTRICAL SYSTEM AND TESTING Troubleshooting SPEED CONTROLLER WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV SETTING (READING WITH OBC POWERED-UP AND ACCELERATOR PEDAL DEPRESSED) Figure 11-16 Pin 6 Test 10. The multimeter should indicate full battery voltage (approximately 48 volts) when the accelerator pedal is pressed.
Page 44 ELECTRICAL SYSTEM AND TESTING Troubleshooting 4. Place a jumper wire with an alligator clip between the B– terminal of the speed controller (use alligator clip for this connection) and pin 7 (orange/white wire) of the 16-pin connector (Figure 11-17, Page 11-30). See following CAUTION. CAUTION •...
Page 45 ELECTRICAL SYSTEM AND TESTING Troubleshooting CAUTION • Do not fully insert probes into the 16-pin plug. Doing so can result in a poor connection. 5. Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first. Tighten battery terminals to 110 in-lb (12.4 N·m).
Page 46 ELECTRICAL SYSTEM AND TESTING Troubleshooting Test Procedure 9F – Pin 9 See General Warning, Section 10, Page 10-1. Pin 9 in the 16-pin connector provides a connection point for the Tow/Run switch to the speed controller. The switch provides a +48 volt signal to the speed controller through pin 9 when the Tow/Run switch is in the RUN position.
Page 47 ELECTRICAL SYSTEM AND TESTING Troubleshooting • Continuity of the wires in the wire harness • Tow/Run switch for proper operation. See Test Procedure 6 – Tow/Run Switch on page 11-21. 7. If items in step 6 test out okay, the diode has failed open and should be removed from the harness. See Pin 9 Diode Removal, Section 13, Page 13-16.
Page 48 ELECTRICAL SYSTEM AND TESTING Troubleshooting • Tow/Run switch for proper operation. See Test Procedure 6 – Tow/Run Switch on page 11-21. • Key switch for proper operation. See Test Procedure 8 – Key Switch and MCOR Limit Switch Cir- cuit on page 11-23. Test Procedure 9H –...
Page 49 ELECTRICAL SYSTEM AND TESTING Troubleshooting TEST PROCEDURE 10 – ONBOARD COMPUTER SILICON-CONTROLLED RECTIFIER (SCR) CIRCUIT See General Warning, Section 10, Page 10-1. The silicon controlled rectifier (SCR), located inside the onboard computer, acts as a switch on the negative side of the circuit. This allows the onboard computer (OBC) to control the battery charging current.
Page 50 ELECTRICAL SYSTEM AND TESTING Troubleshooting TEST PROCEDURE 13 – MOTOR SPEED SENSOR See General Warning, Section 10, Page 10-1. Motor Speed Sensor Test with the IQDM Handset ý 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 51 ELECTRICAL SYSTEM AND TESTING Troubleshooting 6. 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. 6 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 52 ELECTRICAL SYSTEM AND TESTING Troubleshooting TEST PROCEDURE 15 – FORWARD/REVERSE ROCKER SWITCH See General Warning, Section 10, Page 10-1. Forward/Reverse Rocker Switch Test with the IQDM Handset 1. Turn the key switch to the OFF position and place the Forward/Reverse switch in the NEUTRAL position. 2.
Page 53 ELECTRICAL SYSTEM AND TESTING Troubleshooting dash out slightly from under edge of cowl brace. 2.4. Pull center dash out from the frame and disconnect the wires from the electrical components mounted on the dash panel. Do not allow wires to touch. See following NOTE. NOTE: Take care to prevent key switch terminals and wires from touching the metal frame around the dash.
Page 54 6. 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. 1 positive post. The reading should be approximately 48 volts (full battery voltage).
Page 55: Communication Display Module (Cdm)
Last charge termination type (1 = Incomplete, 2 = DVDT, 4 = Normal, 8 = Max. timer). POWER Club Car PART #17075 Figure 11-23 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 56: Using The Cdm To Retrieve Data From The Onboard Computer
ELECTRICAL SYSTEM AND TESTING Troubleshooting 2 – Indicates a back-up charge program was employed by the OBC to complete the charge cycle if a normal charge (4) is not possible. DVDT refers to an increase in voltage within a time period. The OBC monitors battery voltage during charging and will terminate the charge when the voltage does not increase within the time period.
Page 57: Cdm Troubleshooting Guide
Troubleshooting 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 CDM battery...
Page 59: Section 12 - Iq Display Module (Iqdm) Series 2 And Iqdm-P Diagnostics
Note: Seat shown in illustration may not match all models. Figure 12-1 IQDM Jack Under Seat in Extended Figure 12-2 IQDM Jack Under Instrument Panel Position (DS Villager 4) (Turf 1/Carryall 1) 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement Page 12-1...
Page 60: Introductory Display
IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Introductory Display INTRODUCTORY DISPLAY Immediately after the handset is connected to the vehicle, it begins loading the vehicle speed controller infor- mation. After a few seconds, the screen displays the following menu items: •...
Page 61 IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Menu Navigation DISPLAY SCREEN NAVIGATION BUTTON CHANGE VALUE BUTTON BOOKMARK BUTTONS Figure 12-3 Handset Controls The following menus are accessible on the IQDM Series 2 handset: Program (IQDM-P only) The program menu allows the user to view and change custom speed controller settings. See Program Menu, Section 18, Page 18-2.
Page 62: Monitor Menu
IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Monitor Menu Information The information menu displays the model number, serial number, manufacturer date and software version of the speed controller. See Information, Section 12, Page 12-14. Programmer Setup The programmer setup menu allows the user to set the LCD contrast, display the fault history of the program- mer as well as various other information pertaining to the handset such as model number, serial number, OEM information, etc.
Page 63 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, Section 18, Page 18-3.
Page 64: Faults Menu
IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS 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 dis- played often indicate which components in the electrical system need to be tested.
Page 65 IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Faults Menu 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 66 IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Faults Menu Depending on the type of fault, the controller will attempt to recover immediately after the condition clears or after the accelerator pedal has been cycled (released and pressed again). CONTROLLER CONTROLLER FAULT CONTROLLER ATTEMPTS...
Page 67 IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Faults Menu Main Welded If the speed controller detects that the solenoid contacts are welded closed, a main welded fault is detected. Main Driver On If the FET that controls the closing of the solenoid contacts is found to be energized when it should not be, a main driver on fault is detected by the speed controller.
Page 68 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, Section 18, Page 18-3.
Page 69: Functions Menu
IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS 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 70: Write Settings To Controller
IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Functions Menu All Controller Settings Saved in Programmer. Executing... OK (+) OK (+) Figure 12-4 Handset Executing Figure 12-5 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 71: Reset All Settings
IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Functions Menu 6. Select settings. 7. Select write settings to controller. 8. Press + on the change value button to confirm the operation. 9. 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 12-4).
Page 72: Information
IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Information Resetting All Settings 1. During an active session when the settings need to be returned to the original values (the values that were active at the beginning of the session), scroll to the functions menu and select. 2.
Page 73: Information
IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS IQDM and IQDM-P Handset Troubleshooting The following faults can be detected within the handset: CODE NUMBER TEXT DISPLAYED Time out error detect, no response from controller Communication error with controller Error in handset Handset does not support this function Serial port overrun error Security lockout on program menu...
Page 74 IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS IQDM and IQDM-P Handset Troubleshooting TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Handset display screen is blank Handset cord and/or adaptor is See Plugging the Handset into the disconnected Vehicle on page 1. Vehicle batteries –...
Page 75: Test Procedures
IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Test Procedures TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Handset is “locked-up” – buttons do Disconnect the IQDM cord from the not respond Handset malfunction vehicle. Wait a few seconds and reconnect the handset to the vehicle Vehicle batteries –...
Page 76 TEST PROCEDURE 3 – IQDM JACKS See General Warning, Section 10, Page 10-1. Test Procedure 3A – IQDM Jack (Located Under Seat) (DS Villager 4) 1. Lift and remove seat and locate IQDM jack under seat (Figure 12-8, Page 12-18).
Page 77 IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Test Procedures 3. Check the IQDM jack mounted under the instrument panel. 3.1. Remove the center dash panel (Figure 12-9, Page 12-19). 3.1.1. Remove the plastic cap (1) covering the mounting screw (2) on each side of the center dash panel (3) (Figure 12-9, Page 12-19).
Page 78 IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Test Procedures 4.7. If the handset functions when connected directly to the speed controller, the adapter plug or vehicle wire harness should be thoroughly tested. See Test Procedure 2 – Handset Cord Adaptor on page 12-18.
Page 79: Section 13 - Electrical Components
SECTION 13 – ELECTRICAL COMPONENTS ý DANGER • See General Warning, Section 10, Page 10-1. ý WARNING • See General Warning, Section 10, Page 10-1. KEY SWITCH See General Warning, Section 10, Page 10-1. Testing the Key Switch See Test Procedure 8, Section 11, Page 11-23. Key Switch Removal 1.
Page 80 Key Switch Removal, Continued: 2.4. DS Villager 4 Vehicles: Pull center dash out approximately 1 inch (2.5 cm) from the frame and then bend the top right corner of the center dash inward while pulling the top of the panel out and down.
Page 81: Forward/Reverse Rocker Switch
1. Disconnect the batteries and discharge the controller. See Disconnecting The Batteries on page 10-3. 2. Vehicles with Forward/Reverse rocker switch housings mounted on the body below the seat: 2.1. DS Villager 4: Remove two screws (3) that hold Forward/Reverse rocker switch housing (2) to body (Figure 13-4, Page 13-5).
Page 82 ELECTRICAL COMPONENTS Forward/Reverse Rocker Switch 4. Vehicles with Forward/Reverse rocker switch mounted on dash panel: 4.1. Install center dash by reversing removal procedure. Make sure key switch terminals do not touch frame and that the center dash panel is properly seated and snapped into place. (Figure 13-1, Page 13-1).
Page 83: Tow/Run Switch
ELECTRICAL COMPONENTS Tow/Run Switch Figure 13-4 Forward/Reverse Rocker Switch Figure 13-5 Forward/Reverse Rocker Switch (DS Villager 4) (Turf 1/ Carryall 1) TOW/RUN SWITCH See General Warning, Section 10, Page 10-1. Testing the Tow/Run Switch See Test Procedure 6, Section 11, Page 11-21.
Page 84 ELECTRICAL COMPONENTS Motor Controller Output Regulator (MCOR) MCOR Removal 1. Disconnect the batteries and discharge the controller. See Disconnecting The Batteries on page 10-3. 2. Place chocks at rear wheels and lift the front of the vehicle with a chain hoist or floor jack. Place jack stands under the round tube crossmember of the frame to support vehicle.
Page 85: Reverse Buzzer
ELECTRICAL COMPONENTS Reverse Buzzer NOTE: The MCOR is keyed to ensure correct positioning on the drive bar. 4. Insert the alignment pins on the MCOR into the holes in the I-beam as shown. 5. Secure the MCOR to the frame I-beam with two hex-head screws (3). Tighten screws to 23 in-lb (2.6 N·m).
Page 86 ELECTRICAL COMPONENTS Solenoid 4.2. Lift the solenoid (3) up and off of the component mounting plate. 5. Slot-mounted solenoid (Figure 13-8, Page 13-8). 5.1. Slide solenoid up to disengage the mounting tabs and remove from component mounting plate.. Figure 13-7 Screw-Mounted Solenoid Figure 13-8 Slot-Mounted Solenoid Solenoid Installation 1.
Page 87: Onboard Computer (Obc)
ELECTRICAL COMPONENTS Solenoid ONBOARD COMPUTER (OBC) See General Warning, Section 10, Page 10-1. Testing the Onboard Computer See Section 11, Test Procedure 2, Page 11-18, Test Procedure 10, Page 11-35, and Test Procedure 11, Page 11-35. Onboard Computer Removal 1. Disconnect the batteries and discharge the controller. See Disconnecting The Batteries on page 10-3. 2.
Page 88 ELECTRICAL COMPONENTS Solenoid Onboard Computer Installation 1. Disconnect the batteries and discharge the controller. See Disconnecting The Batteries on page 10-3. 2. Remove the rear body access panel. 3. Install the OBC onto the component mounting plate by aligning the two holes on the OBC face plate with two holes on component mounting plate.
Page 89: Solid State Speed Controller
ELECTRICAL COMPONENTS Solid State Speed Controller Figure 13-10 Speed Controller Cover SOLID STATE SPEED CONTROLLER See General Warning, Section 10, Page 10-1. Testing the Solid State Speed Controller See Test Procedure 5, Section 11, Page 11-21. Speed Controller Removal 1. Disconnect the batteries and discharge the controller. See Disconnecting The Batteries on page 10-3. 2.
Page 90 ELECTRICAL COMPONENTS Solid State Speed Controller 5. Remove the three self-tapping screws (17) that hold the controller (6) to the component mounting plate and remove the controller from the vehicle. TYPICAL 3 PLACES Figure 13-11 Speed Controller Speed Controller Installation 1.
Page 91: Charger Receptacle
ELECTRICAL COMPONENTS Charger Receptacle 6. Place the Tow/Run switch in the RUN position. 7. Inspect the vehicle for proper operation: • Make sure that the vehicle operates in the forward direction when the Forward/Reverse switch is in the FORWARD position. •...
Page 92: Receptacle Fuse Link
RECEPTACLE FUSE LINK The fuse link on the 48-volt Club Car electric vehicle should not blow under normal operating conditions; how- ever, if the fuse link has blown, the vehicle will not charge and the fuse must be replaced. The fuse link (6) is mounted on top of the charger receptacle in the battery compartment (Figure 13-12, Page 13-14).
Page 93: Battery Warning Light
If the pin 9 diode has failed open, it should be removed from the harness. Instead of replacing the diode with a new one, Club Car recommends installing an IQ Main Dropout Harness (CC P/N 102355201) between the Tow/Run switch and the wire harness.
Page 94 ELECTRICAL COMPONENTS Pin 9 Diode Pin 9 Diode Removal 1. Disconnect the batteries and discharge the controller. See Disconnecting The Batteries on page 10-3. 2. Remove the diode from the gray/white and gray wires as indicated (Figure 13-14, Page 13-16). 3.
Page 95: Ferrite Beads - Ce Mark Vehicles
ELECTRICAL COMPONENTS Ferrite Beads – CE Mark Vehicles FERRITE BEADS – CE MARK VEHICLES These beads bring the vehicle into compliance with EMC requirements for use in the European Union. 2008-2010 MODEL YEARS Figure 13-16 Ferrite Bead Placement (2008-2010 Model Year) 1.
Page 96: Starting 2011 Model Year
ELECTRICAL COMPONENTS Ferrite Beads – CE Mark Vehicles STARTING 2011 MODEL YEAR Figure 13-17 Ferrite Bead Placement (Starting 2011 Model Year) 1. This bead goes around 2 wires (green, white) near the motor. 2. This bead goes around 2 wires (blue, orange) near the motor. 3.
Page 97: Section 14 - Batteries
The outward appearance of these two batteries is similar, but the operating characteristics are very different. The Club Car electric vehicle battery is a deep-cycle battery, and the automotive battery is a “starting, lighting and ignition” (SLI) battery. They should never be substituted for one another.
Page 98: Electrolyte Level
This process creates a finished product free of minerals, having left all the impu- rities in the original water sample. Club Car, along with our battery manufacturers, highly recommends that distilled water be used in electric vehicle batteries.
Page 99: Vibration Damage
If using tap water, Club Car's Service Parts Department offers two different deionizer systems: one for vehi- cles equipped with the Single Point Water System (SPWS) P/N AM1240701 and the other for vehicles without SPWS, P/N AM10974.
Page 100: Battery Charging
The deeper the discharge, the harder it is on the batteries. For this reason, it is recommended that Club Car electric vehicle batteries be charged after each use (pro- vided the charge cycle will not be interrupted and the charger will be allowed to shut off automatically). Placing the batteries on charge after each use reduces the depth of discharge and prolongs battery life.
Page 101: Incoming Ac Service
See following NOTE. NOTE: When vehicles are being rotated, the Club Car CDM (Communication Display Module) can be a very helpful service tool. Monitoring the value of function 3 with the CDM simplifies vehicle usage scheduling.
Page 102: Battery Troubleshooting Chart
BATTERIES Battery Troubleshooting Chart BATTERY TROUBLESHOOTING CHART Vehicle not operating to expectation. Fully Charge Batteries. Battery Charger Test Reading of 6 amps or more. Reading below 6 amps and on-charge voltage above 56 volts. Check electrical system and charger for problems. SeeTroubleshooting Guide On-Charge Voltage Test If problem is not found, go to...
Page 103: Battery Testing - 8 Volt
BATTERIES Battery Testing – 8 Volt BATTERY TESTING – 8 VOLT See General Warning, Section 10, Page 10-1. 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 14-2, Page 14-6).
Page 104 BATTERIES Battery Testing – 8 Volt 3. Squeeze the rubber bulb of the hydrometer and insert into the cell. Slowly release the bulb, drawing elec- trolyte up into the glass tube of the hydrometer. 4. When the float rises off the bottom, adjust the electrolyte level so that the float rides free of the bottom but does not strike the top of the glass tube.
Page 105: Discharge Test
NO. 1 (+) FRONT OF VEHICLE BLACK PROBE TO BATTERY NO. 6 (–) Figure 14-4 Turf 1/Carryall 1 Battery Discharge Test Figure 14-5 DS Villager 4 6x8-Volt Battery Discharge Test 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement Page 14-9...
Page 106 BATTERIES Battery Testing – 8 Volt 3. Check and record the electrolyte temperature of the battery packs. Check cell no. 2 (second cell from positive post) in each battery. 4. Reset discharge machine and turn the tester ON. 5. When the batteries have been discharging for approximately 60 minutes, set the discharge machine to function 3 and check battery set voltage.
Page 107: Battery Troubleshooting Examples
BATTERIES Battery Testing – 8 Volt 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 108: Battery Testing - 12 Volt
BATTERIES Battery Testing – 12 Volt BATTERY TESTING – 12 VOLT See General Warning, Section 10, Page 10-1. 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 14-2, Page 14-6).
Page 109 BATTERIES Battery Testing – 12 Volt 3. Squeeze the rubber bulb of the hydrometer and insert into the cell. Slowly release the bulb, drawing elec- trolyte up into the glass tube of the hydrometer. 4. When the float rises off the bottom, adjust the electrolyte level so that the float rides free of the bottom but does not strike the top of the glass tube.
Page 110: Discharge Test
2. Connect the tester leads to the positive (+) post of battery no.1 and negative (–) post of battery no. 4 (Figure 14-7, Page 14-14). (–) Figure 14-7 DS Villager 4 4x12-Volt Battery Discharge Test 1. RED probe to battery no. 1 (+).
Page 111 BATTERIES Battery Testing – 12 Volt 3. Check and record the electrolyte temperature of the battery packs. Check cell no. 2 (second cell from positive post) in each battery. 4. Reset discharge machine and turn the tester ON. 5. When the batteries have been discharging for approximately 60 minutes, set the discharge machine to function 3 and check battery set voltage.
Page 112: Battery Troubleshooting Examples
BATTERIES Battery Testing – 12 Volt 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 113: Battery Storage
80 °F (26.7 °C) will have to be recharged every few weeks. 5. 48-volt Club Car electric vehicles and compatible battery chargers are designed to be left connected, with AC power to the charger ON, during off-season storage. The storage charge feature will automati- cally charge the batteries as needed throughout the storage period.
Page 114 BATTERIES Battery Replacement (–) Figure 14-8 Battery Cable Removal – DS Villager Figure 14-9 Battery Cable Removal – DS Villager 6x8-Volt Battery Configuration 4x12-Volt Battery Configuration (Viewed from driver side of vehicle) (Viewed from driver side of vehicle) 1. Place TOW/RUN Switch in TOW before disconnecting or 1.
Page 115: Charging A Battery Pack That Has Low Voltage
BATTERIES Charging a Battery Pack that has Low Voltage CHARGING A BATTERY PACK THAT HAS LOW VOLTAGE See the appropriate battery charger maintenance and service manual. 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement Page 14-19...
Page 117: Section 15 - Battery Charger
SECTION 15 – BATTERY CHARGER Refer to the appropriate battery charger maintenance and service manual. 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement Page 15-1...
Page 119: Section 16A - Motor (Model 5Bc59Jbs6390)
SECTION 16A – MOTOR (MODEL 5BC59JBS6390) ý DANGER • See General Warning, Section 10, Page 10-1. ý WARNING • See General Warning, Section 10, Page 10-1. GENERAL INFORMATION The electric vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. The shunt-wound motor is designed for use on IQ System vehicles only.
Page 120: Motor
MOTOR (MODEL 5BC59JBS6390) Motor TEST PROCEDURE 2 – ARMATURE CIRCUIT OPEN See General Warning, Section 10, Page 10-1. 1. Disconnect the batteries and discharge the controller. See Disconnecting The Batteries on page 10-3. 2. Disconnect wires from the A1 and A2 terminals on the motor using two wrenches to prevent posts from turning.
Page 121 MOTOR (MODEL 5BC59JBS6390) Motor Figure 16a-1 Lift Vehicle with Floor Jack Figure 16a-2 Vehicle Supported on Jack Stands 5. Remove both rear wheels. 6. 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 16a-3, Page 16a-3).
Page 122 MOTOR (MODEL 5BC59JBS6390) Motor Motor Disassembly 1. Before beginning disassembly, place match marks on the motor end shield and stator shell, then place the motor in a vice with wooden blocks as shown (Figure 16a-4, Page 16a-4). 2. Remove the four bolts (8) securing the end shield (10) to the stator shell (2). 3.
Page 123: Motor Component Testing And Inspection
MOTOR (MODEL 5BC59JBS6390) Motor MOTOR COMPONENT TESTING AND INSPECTION See General Warning, Section 10, Page 10-1. ARMATURE Visual Inspection Disassemble the motor and carefully inspect the armature for the following characteristics: • Burned, charred or cracked insulation • Improperly cured varnish •...
Page 124: Field Windings Inspection
MOTOR (MODEL 5BC59JBS6390) Motor ARMATURE CORE COMMUTATOR Figure 16a-6 Armature Test FIELD WINDINGS INSPECTION Burned or scorched insulation on the field windings indicates the motor has overheated due to overloads or grounded or shorted coil windings. If the insulation on the field windings is scorched, replace the motor or the stator shell assembly.
Page 125: Bearing Inspection
MOTOR (MODEL 5BC59JBS6390) Motor BEARING INSPECTION 1. Use a clean cloth to wipe the carbon dust off of the bearing. Inspect the bearing by spinning it by hand and checking for both axial (A) and radial (B) play (Figure 16a-8, Page 16a-7). 2.
Page 126 MOTOR (MODEL 5BC59JBS6390) Motor TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 3 PLACES Figure 16a-9 Motor – Model 5BC59JBS6390 Page 16a-8 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement...
Page 127: Speed Sensor Magnet Inspection
MOTOR (MODEL 5BC59JBS6390) Reconditioning the Motor SPEED SENSOR MAGNET INSPECTION Inspect the speed sensor magnet (18) for rust, wear, and cracks (Figure 16a-9, Page 16a-8). Replace the magnet if necessary. SPEED SENSOR MAGNET REMOVAL 1. To remove the speed sensor magnet (18), remove the motor bearing (Figure 16a-9, Page 16a-8). See Bearing Removal on page 16a-7.
Page 128: Motor Assembly
MOTOR (MODEL 5BC59JBS6390) Reconditioning the Motor MOTOR ASSEMBLY See General Warning, Section 10, Page 10-1. 1. If the bearing has been removed, replace the bearing. See Bearing Installation on page 16a-7. 2. Install the brushes. See following NOTE. NOTE: When installing new brushes, remove and replace brushes one at a time. This method ensures the terminals and brushes will be properly positioned in the rigging.
Page 129 MOTOR (MODEL 5BC59JBS6390) Reconditioning the Motor 2.3. Slide the armature, bearing end first, into the stator shell. Make sure the brushes are held back while positioning the armature for proper commutator/brush contact. Release the brushes and place the springs outside the brushes so the brushes are being held against the commutator. See following CAUTION.
Page 130: Motor Installation
MOTOR (MODEL 5BC59JBS6390) Motor Installation MOTOR INSTALLATION See General Warning, Section 10, Page 10-1. 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 131 MOTOR (MODEL 5BC59JBS6390) Motor Installation 4. Install motor on transaxle. 4.1. Slide the motor coupling onto the transaxle input shaft. See following NOTE. NOTE: The coupling will push any excess grease on the input shaft along the shaft toward the transaxle. When the motor is pushed onto the input shaft, the motor adapter ring (1) will not bottom out against the transaxle housing (Figure 16a-9, Page 16a-8).
Page 132 MOTOR (MODEL 5BC59JBS6390) Motor Installation Motor Installation, Continued: 6. Insert the mounting bolts through the spring shackles and the bushings in the leaf spring eyes and install locknuts. Tighten the bolts to 23 ft-lb (31 N·m). See Section 9 – Rear Suspension in the appropriate maintenance and service manual.
Page 133: Motor Speed Sensor
MOTOR (MODEL 5BC59JBS6390) Motor Speed Sensor MOTOR SPEED SENSOR See General Warning, Section 10, Page 10-1. Testing the Motor Speed Sensor See Test Procedure 13, Section 11, Page 11-36. Motor Speed Sensor Removal 1. Disconnect the batteries and discharge the controller. See Disconnecting The Batteries on page 10-3. 2.
Page 135: Section 16B - Motor (Models Ej4-4001 And Ej8-4001A)
SECTION 16B – MOTOR (MODELS EJ4-4001 AND EJ8-4001A) ý DANGER • See General Warning, Section 10, Page 10-1. ý WARNING • See General Warning, Section 10, Page 10-1. GENERAL INFORMATION The electric vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. The shunt-wound motor is designed for use on IQ System vehicles only.
Page 136 MOTOR (MODELS EJ4-4001 AND EJ8-4001A) External Motor Testing CONTINUITY TEST MOTOR TERMINALS RESULT A1 to A2 Continuity F1 to F2 A1 to F1 No Continuity A1 to F2 A2 to F1 No Continuity A2 to F2 A1 to Ground No Continuity A2 to Ground F1 to Ground No Continuity...
Page 137: Motor
MOTOR (MODELS EJ4-4001 AND EJ8-4001A) Motor MOTOR See General Warning, Section 10, Page 10-1. MOTOR REMOVAL 1. Disconnect the batteries and discharge the controller. See Disconnecting The Batteries on page 10-3. 2. Disconnect wires from the terminals on the motor using two wrenches to prevent posts from turning. Label the wires to ensure proper reconnection.
Page 138 MOTOR (MODELS EJ4-4001 AND EJ8-4001A) Motor 8. To gain easier access to the motor, lower the transaxle as low as it will go. If more room is needed, remove the jack from beneath the transaxle and allow the springs to rest on the floor (Figure 16b-3, Page 16b-4).
Page 139: Motor Disassembly
MOTOR (MODELS EJ4-4001 AND EJ8-4001A) Motor MOTOR DISASSEMBLY 1. Before beginning disassembly, place match marks on the motor end cap and motor frame. 2. Remove speed sensor and magnet. 2.1. Remove the two screws (25) that secure the speed sensor (10) to the end cap (11) (Figure 16b-15, Page 16b-11).
Page 140 MOTOR (MODELS EJ4-4001 AND EJ8-4001A) Motor ý CAUTION • Removing the armature from the end cap requires two people: one to operate the press, and another to hold the armature. Failure to heed this CAUTION could result in personal injury and/or damage to the armature resulting from an unsupported armature falling after it becomes disengaged from the end cap bearing.
Page 141: Motor Component Testing And Inspection
MOTOR (MODELS EJ4-4001 AND EJ8-4001A) Motor Component Testing and Inspection Figure 16b-10 Brush Rigging Figure 16b-11 Bearing Retaining Ring MOTOR COMPONENT TESTING AND INSPECTION See General Warning, Section 10, Page 10-1. ARMATURE INSPECTION AND TESTING 1. Remove the motor from the vehicle. See Motor Removal, Section 16b, Page 16b-3. 2.
Page 142: Motor Frame And Field Windings Inspection
MOTOR (MODELS EJ4-4001 AND EJ8-4001A) Motor Component Testing and Inspection Armature Ground Test CAUT ION • Do not submerge the armature in solvent. NOTE: Before testing the armature, wipe it clean with a clean cloth. Remove any carbon dust and metal particles from between the commutator bars.
Page 143 MOTOR (MODELS EJ4-4001 AND EJ8-4001A) Motor Component Testing and Inspection 3. Inspect the brush springs (14) (Figure 16b-15, Page 16b-11). Replace springs that are discolored from heat (light gold or blue tinted). 4. Test the brush springs for proper tension. 4.1.
Page 144 MOTOR (MODELS EJ4-4001 AND EJ8-4001A) Motor Component Testing and Inspection Terminal Insulator Inspection 1. Remove the motor from the vehicle. See Motor Removal, Section 16b, Page 16b-3. 2. Remove the terminal insulators by performing steps 1 through 12 of Motor Disassembly on page 16b-5. 1.
Page 145 MOTOR (MODELS EJ4-4001 AND EJ8-4001A) Motor Component Testing and Inspection TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 3 PLACES Figure 16b-15 Motor – Models EJ4-4001 and EJ8-4001A 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement Page 16b-11...
Page 146: Reconditioning The Motor
MOTOR (MODELS EJ4-4001 AND EJ8-4001A) Reconditioning the Motor RECONDITIONING THE MOTOR See General Warning, Section 10, Page 10-1. 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 147 MOTOR (MODELS EJ4-4001 AND EJ8-4001A) Motor Assembly Figure 16b-16 Brush Rigging Figure 16b-17 Retracted Brushes Figure 16b-18 Armature Installation Figure 16b-19 Brush Setting 2.5. One at a time, push the brushes back until they are completely retracted into their mounting slots and the spring pressure holds them in the retracted position as shown (Figure 16b-17, Page 16b-13).
Page 148: Motor Installation
MOTOR (MODELS EJ4-4001 AND EJ8-4001A) Motor Installation MOTOR INSTALLATION See General Warning, Section 10, Page 10-1. 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 149 MOTOR (MODELS EJ4-4001 AND EJ8-4001A) Motor Installation 4. Install motor on transaxle. 4.1. Slide the motor coupling onto the transaxle input shaft. See following NOTE. NOTE: The coupling will push any excess grease on the input shaft along the shaft toward the transaxle. When the motor is pushed onto the input shaft, the motor housing will not bottom out against the transaxle housing (Figure 16b-15, Page 16b-11).
Page 150 MOTOR (MODELS EJ4-4001 AND EJ8-4001A) Motor Installation 5. 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. 6.
Page 151: Section 17 - Transaxle (Type G)
SECTION 17 – TRANSAXLE (TYPE G) ý DANGER • See General Warning, Section 10, Page 10-1. ý WARNING • See General Warning, Section 10, Page 10-1. LUBRICATION See General Warning, Section 10, Page 10-1. 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 17-5, Page 17-3).
Page 152 TRANSAXLE (TYPE G) Axle Bearing and Shaft Axle Shaft and Oil Seal Removal, Continued: NOTE: Do not discard the adapter ring. If the adapter ring is lost or damaged, the axle tube will have to be replaced. 6.2. Use a press to separate the axle oil seal (15) from the adapter ring (39) (Figure 17-3, Page 17-2). Retain the adapter ring and discard the oil seal.
Page 153 TRANSAXLE (TYPE G) Axle Bearing and Shaft TYPICAL 6 PLACES Figure 17-5 Transaxle – Type G 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement Page 17-3...
Page 154: Axle Bearing
TRANSAXLE (TYPE G) Axle Bearing and Shaft Axle Shaft and Oil Seal Installation 1. If previously removed, install a new oil seal. 1.1. Clean seal seat in the adapter ring (39) (Figure 17-3, Page 17-2). 1.2. Place a new seal (15) in the adapter ring with the seal lip facing toward the adapter ring lip (1) (Figure 17-3, Page 17-2).
Page 155: Transaxle
TRANSAXLE (TYPE G) Transaxle TRANSAXLE See General Warning, Section 10, Page 10-1. TRANSAXLE REMOVAL 1. Place chocks at the front wheels and slightly loosen lug nuts on both rear wheels. 2. Place a floor jack under the transaxle and raise the rear of the vehicle. Position jack stands under the frame crossmember between the spring mount and the side stringer, just forward of each rear wheel.
Page 156 TRANSAXLE (TYPE G) Transaxle Transaxle Removal, Continued: 5. Disconnect the shock absorbers from their lower mounts (Figure 17-8, Page 17-5). 6. Disconnect the four motor wires. Use two wrenches to prevent the post from turning. 7. With a floor jack supporting the transaxle, remove lower spring shackle nuts and bolts. Position shackles so they are clear of springs (Figure 17-9, Page 17-5).
Page 157: Transaxle Disassembly, Inspection, And Assembly
TRANSAXLE (TYPE G) Transaxle Disassembly, Inspection, and Assembly APPEARANCE OF MOTOR MAY BE DIFFERENT FROM THE MOTOR SHOWN ABOVE. Figure 17-12 Motor Positioning Bolt (not present on EJ8-4001A motors) TRANSAXLE DISASSEMBLY, INSPECTION, AND ASSEMBLY See General Warning, Section 10, Page 10-1. TRANSAXLE DISASSEMBLY AND INSPECTION 1.
Page 158 TRANSAXLE (TYPE G) Transaxle Disassembly, Inspection, and Assembly Transaxle Disassembly and Inspection, Continued: 7. Press the bearing (18) off the intermediate gear assembly (Figure 17-5, Page 17-3). PRESS RAM ARBOR Figure 17-13 Intermediate Gear Assembly 8. Disassemble the differential gear case: 8.1.
Page 159: Transaxle Assembly
TRANSAXLE (TYPE G) Transaxle Disassembly, Inspection, and Assembly DIFFERENTIAL GEAR LEFT DIFFERENTIAL GEAR CASE Figure 17-15 Differential Pin Figure 17-16 Left Differential 8.6. Remove the differential gears and thrust plates (3 and 4). 8.7. Inspect the bearings (13) of the differential case (26) and replace them if they are damaged (Figure 17-5, Page 17-3).
Page 160: Transaxle Installation
TRANSAXLE (TYPE G) Transaxle Installation Transaxle Assembly, Continued: 7. Install both dowel pins (25) in the transaxle housing (20) (Figure 17-5, Page 17-3). 8. Install left half of transaxle housing: 8.1. Place a 1/8-inch (3 mm) bead of Three Bond liquid gasket on mating surface of housing. 8.2.
Page 161 TRANSAXLE (TYPE G) Transaxle Installation 3. Install the two U-bolts, jounce bumper mount (if required), and spacers, lockwashers, and nuts. Tighten the nuts to 25 ft-lb (34 N·m). Tighten the U-bolt nuts so an equal amount of thread is visible on each leg of the bolt.
Page 163: Section 18 - Iq Display Module (Iqdm-P) Programming
Note: Seat shown in illustration may not match all models. Figure 18-1 IQDM Jack Under Seat in Extended Posi- Figure 18-2 IQDM Jack Under Instrument Panel (Turf tion (DS Villager 4) 1/Carryall 1) 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement Page 18-1...
Page 164: Program Menu
IQ DISPLAY MODULE (IQDM-P) PROGRAMMING Plugging the Handset into the Vehicle 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 18-3). 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 165: Fast Accel
4, does not conform to 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 infor- mation on this feature, contact your local Club Car distributor or dealer. 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement...
Page 166 IQ DISPLAY MODULE (IQDM-P) PROGRAMMING Plugging the Handset into the Vehicle Page 18-4 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement...
Page 167 INDEX armature, motor charger receptacle see motor, armature fuse link ............13-14 installation ..........13-14 removal ............13-14 installation ............13-13 batteries ...............14-1 removal ............13-13 see also battery charger testing ............11-35 care ..............14-1 communication display module (CDM) charging ............14-4 function codes ..........11-41 deep discharge ..........14-4 retrieving data from ........11-42 electrolyte troubleshooting ..........11-43...
Page 168 INDEX transaxle, type g ..........17-7 speed sensor magnet inspection ........16a-9, 16b-10 installation ..........16a-9 removal ............. 16a-9 key switch testing ............11-21 installation ............13-2 see test procedures, motor removal ............13-1 zero speed detect ..........11-1 testing ............11-23 motor braking see regenerative braking motor controller output regulator (MCOR)
Page 169 INDEX speed sensor removal ............17-5 troubleshooting ..........11-2 see motor, speed sensor battery troubleshooting examples ..14-11, 14-16 communication display module (CDM) ..11-43 IQDM and IQDM-P handset ......12-15 test procedures troubleshooting guide 1 ........11-11 8 – MCOR limit switch ........11-23 troubleshooting guide 2 ........11-14 test procedures, electrical system 1 –...
Page 171 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 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement...
Page 173 Club Car NOTES...
Page 174 Club Car NOTES...
Page 176 Club Car, LLC www.clubcar.com P.O. Box 204658 Phone 1.706.863.3000 Augusta, GA 30917-4658 1.800.ClubCar Int’l +1 706.863.3000 1.706.863.5808...

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Carryall 1 2008 turf

Club Car DS Villager 4 Maintenance And Service Manual Supplement

Section 10 - Periodic Maintenance

Section 11 - Electrical System and Testing

Section 12 - Iq Display Module (Iqdm) Series 2 and Iqdm-P Diagnostics

Section 13 - Electrical Components

Section 14 - Batteries

Section 15 - Battery Charger

Section 16A - Motor (Model 5Bc59Jbs6390)

Section 16B - Motor (Models Ej4-4001 and Ej8-4001A)

Section 17 - Transaxle (Type G)

Section 18 - Iq Display Module (Iqdm-P) Programming

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