Page 1 2019 Transporter Maintenance and Service Manual Electric Vehicle with QuiQ™ ™ ™ Charger Manual Number 105355114 Edition Code B...
Page 3 To find your local authorized Club Car dealer, visit www.clubcardealer.com, call 1-800-ClubCar (258–2227), or scan this Quick Response (QR) code to be taken to the Club Car dealer locator. Refer to Figure 1. Download a QR code reader such as RedLaser or Barcode Scanner to your cell phone or tablet.
Page 4 NOTE: This manual represents the most current information at the time of publication. Club Car is continually working to further improve its vehicles and other products. These improvements may affect servicing procedures.
Page 5: Table Of Contents
CONTENTS SECTION 1 — Safety............................1-1 Safety Details ..............................1-1 Personal Safety ............................1-1 Machine Safety............................1-1 Information..............................1-1 General Warnings............................1-2 Disabling the Vehicle..........................1-3 Disconnecting the Batteries – Electric Vehicles .................... 1-3 Connecting the Batteries – Electric Vehicles ....................1-4 Recycling Lead-Acid Batteries ........................
Page 6 Electric Bed Lift Installation ........................4-21 Floor Mat ..............................4-22 Floor Mat Removal ..........................4-22 Floor Mat Installation..........................4-22 Rear-Facing Seat ............................4-23 Trailer Hitch..............................4-24 Trailer Hitch Removal..........................4-24 Trailer Hitch Installation..........................4-24 Electrolyte Tray ............................4-25 Electrolyte Tray Removal ......................... 4-26 Electrolyte Tray Installation........................
Page 7 Rack and Pinion Inspection ........................7-7 Rack and Pinion Removal .......................... 7-7 Rack and Pinion Disassembly ........................7-8 Rack and Pinion Assembly ........................7-10 Rack and Pinion Installation ........................7-13 Tie Rod and Drag Link ..........................7-14 Tie Rod and Drag Link Removal ....................... 7-14 Tie Rod and Drag Link Installation ......................
Page 8 Serial Number ............................11-5 Hardware Version .............................11-5 Protocol Version ............................11-5 Param Block Version..........................11-5 MFG Date Code ............................11-5 OS Version...............................11-5 SM Version ..............................11-5 VCL App Version ............................11-5 Parameters ..............................11-6 Settings ..............................11-6 Amp Hours...............................11-9 Access Codes ............................11-9 Vehicle ID ..............................11-9 Monitor Menu ............................. 11-11 Speed In ..............................
Page 9 Amp Hours Display ..........................11-16 LIN ................................ 11-16 Diagnostics Menu ............................11-17 Present Errors Folder..........................11-17 Fault History Folder ..........................11-17 System Faults ............................11-17 Fault Recovery ............................11-19 Fault Descriptions............................11-20 01 Throttle Fault 1 ..........................11-20 02 Low Battery Voltage ........................... 11-20 03 Overvoltage ............................
Page 10 Troubleshooting Guide 1 .......................... 12-6 Troubleshooting Guide 2 .......................... 12-9 Test Procedures ............................12-11 Testing Basics ............................12-11 SECTION 13 — Electrical Components......................13-1 Key Switch ..............................13-1 Testing the Key Switch ..........................13-1 Key Switch Removal ..........................13-1 Key Switch Installation ..........................13-1 Forward/Reverse Rocker Switch........................
Page 11 Observation............................. 14-2 Measuring Voltage of Battery Set......................14-2 Battery Cell Numbering ..........................14-2 Battery Testing – 6 Volt ..........................14-3 Battery Regrouping............................14-3 Battery Replacement ........................... 14-5 Battery Care..............................14-6 Water Quality ............................14-6 Deionizer ..............................14-7 Battery Care – Vehicles Equipped with the Single-Point Watering System (SPWS) ........14-8 Battery Care –...
Page 12 Axle Bearing............................17-4 Transaxle ..............................17-5 Transaxle Removal ..........................17-5 Transaxle Disassembly, Inspection, and Assembly..................17-8 Transaxle Disassembly and Inspection...................... 17-8 Transaxle Assembly..........................17-10 Transaxle Installation ..........................17-11 SECTION 18 — Wiring Diagrams........................18-1 General Information ............................. 18-1 Index ................................Index-1 Page x 2019 Transporter Maintenance and Service Manual...
Page 13: Section 1 - Safety
SAFETY DETAILS 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 14: General Warnings
• The vehicle will not provide protection from lightning, flying objects, or other storm-related hazards. If caught in a storm while driving a Club Car vehicle, exit the vehicle and seek shelter in accordance with applicable safety guidelines for your location.
Page 15: Disabling The Vehicle
SAFETY General Warnings WARNING • Wear safety glasses or approved eye protection when servicing the vehicle or battery charger. Wear a full face shield and rubber gloves when working on or near batteries. • Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when servicing the vehicle or battery charger.
Page 16: Connecting The Batteries - Electric Vehicles
Responsibility for environmental protection 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 17: International Safety Symbols On Batteries
SAFETY General Warnings INTERNATIONAL SAFETY SYMBOLS ON BATTERIES Anyone using, repairing, or servicing the vehicle must understand and heed the safety symbols on the vehicle battery or batteries. 1. Shield eyes. 3. No smoking, no open flames, no sparks. 5. Battery acid hazard. 2.
Page 18 General Warnings SAFETY Pagination Page Page 1-6 2019 Transporter Maintenance and Service Manual...
Page 19: Section 2 - Vehicle Specifications
SECTION 2 — VEHICLE SPECIFICATIONS VEHICLE SPECIFICATIONS Vehicle Specifications VEHICLE SPECIFICATIONS SPECIFICATIONS TRANSPORTER POWER SOURCE Drive motor: Direct drive, 48 volts DC, shunt wound, 3.1 hp ● Transaxle: Double reduction helical gear with 12.28:1 direct drive axle ● Electrical system: 48 volts DC, reduced speed reverse ●...
Page 20 Vehicle Specifications VEHICLE SPECIFICATIONS SPECIFICATIONS TRANSPORTER Intersecting aisle clearance 123.9 in (314.7 cm) Floorboard height 12.5 in (31.75 cm) Load bed height 29.5 in (74.93 cm) 37 x 47.5 x 10.5 in Load bed size: Box bed dimensions (93.9 x 120.6 x 26.6 cm) Load bed size: Flat bed dimensions 36.5 x 48.8 in (92.7 x 123.9 cm) Vehicle rated capacity: With boxbed (Level surface only)
Page 21: Quiq Battery Charger Specifications
VEHICLE SPECIFICATIONS Vehicle Specifications QUIQ BATTERY CHARGER SPECIFICATIONS QUIQ BATTERY CHARGER SPECIFICATIONS AC INPUT AC Voltage – range 85 to 265 VAC (acceptable) AC Voltage – nominal 120 to 230 VAC Frequency 45 to 65 Hz AC Power Factor – nominal >0.99 @ 120 VAC / >0.98 @ 230 VAC POWER CONSUMPTION Max:...
Page 22 Vehicle Specifications VEHICLE SPECIFICATIONS Pagination Page Page 2-4 2019 Transporter Maintenance and Service Manual...
Page 23: Section 3 - General Information
• See General Warnings on page 1-2. 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 24: Storing The Vehicle
Storing the vehicle GENERAL INFORMATION 2843 Figure 3-1 Serial Number Decal STORING THE VEHICLE See General Warnings on page 1-2. WARNING • Turn the key switch to the OFF position, remove the key, and leave the Forward/Reverse handle or switch in the NEUTRAL position during storage. This is to prevent unintentionally starting the vehicle or a fire hazard.
Page 25: Returning The Stored Vehicle To Service
GENERAL INFORMATION Storing the vehicle Immediately Prior to Storage, Perform the Following Steps Unload the vehicle so that tires are supporting only the weight of the vehicle. Turn the key switch to the OFF position, remove the key, and leave the Forward/Reverse switch in the NEUTRAL position during storage.
Page 26 Storing the vehicle GENERAL INFORMATION Pagination Page Page 3-4 2019 Transporter Maintenance and Service Manual...
Page 27: Section 4 - Body And Trim
SECTION 4 — BODY AND TRIM DANGER Body and Trim • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. CLEANING THE VEHICLE See General Warnings on page 1-2. CAUTION • Do not use detergents or cleaning solvents that contain ammonia, aromatic solvents, or alkali materials on body panels or seats.
Page 28: Front Body Repair
Front Body Repair BODY AND TRIM CAUTION • To prevent damage to the vehicle when removing difficult stains or heavy soiling, remove the seat from the vehicle first. FRONT BODY REPAIR See General Warnings on page 1-2. LIGHT SCRATCHES Clean entire area to be repaired with clean, clear water. Using 1200 grit sandpaper, water-sand entire area of scratch until original scratch is no longer visible, either with finishing sander or wet sanding block.
Page 29: Brushguard Installation
BODY AND TRIM Front Body Remove the bolts (1) (Figure 4-1, Page 4-3). Remove the screws (2) and washers (3). Remove the brushguard (4). BRUSHGUARD INSTALLATION Position the brushguard (4) onto the vehicle (Figure 4-1, Page 4-3). Install the washers (3), screws (2), and bolts (1). Tighten the bolts to 36 ft·lb (49 N·m). Tighten the screws to 25 ft·lb (34 N·m).
Page 30: Cowl Removal
Front Body BODY AND TRIM COWL REMOVAL Park vehicle and chock tires. Disconnect the batteries. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-3. The cowl is secured by tabs located behind the front fenders (2), and under the lip of the dash (1) (Figure 4-2, Page 4-5).
Page 31 BODY AND TRIM Front Body 2846 Figure 4-2 Front Cowl 2019 Transporter Maintenance and Service Manual Page 4-5...
Page 32: Grille Removal
Front Body BODY AND TRIM GRILLE REMOVAL Park vehicle and chock the tires. Disconnect the batteries. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-3. Remove HD bumper (if equipped). See Brushguard Removal, Section 4, Page 4-2. Remove cowl. See Cowl Removal on page 4-4. Loosen and remove the two M6 self-tapping fasteners (1) at the top of grille (7).
Page 33 BODY AND TRIM Front Body 2844 Figure 4-3 Front Grille, Bumper, and Side Fenders 2019 Transporter Maintenance and Service Manual Page 4-7...
Page 34: Front Bumper And Side Fender Removal
Front Body BODY AND TRIM FRONT BUMPER AND SIDE FENDER REMOVAL Park the vehicle, chock tires. Disconnect the batteries. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-3. Remove HD bumper, (if equipped). See Brushguard Removal on page 4-2. Remove the front cowl.
Page 35: Instrument Panel Removal
BODY AND TRIM Front Body INSTRUMENT PANEL REMOVAL Disconnect the batteries. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-3. Remove front cowl. See Cowl Removal, Section 4, Page 4-4. From the inside of the dash, press upper snap tabs (1) of the instrument panel inward to release from dash. Then push the instrument panel near the bottom (2) to pop out the lower body clips (be careful not to pry the lower clips off).
Page 36: Dash Removal
Front Body BODY AND TRIM DASH REMOVAL Disconnect the batteries. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-3. Remove cowl. See Cowl Removal on page 4-4. Remove steering wheel. See Steering Wheel Removal, Section 7, Page 7-1. Disconnect instrument panel wiring.
Page 37 BODY AND TRIM Front Body 2863 Figure 4-5 Dash Assembly 2019 Transporter Maintenance and Service Manual Page 4-11...
Page 38: Tilt Bed
Tilt Bed BODY AND TRIM TILT BED See General Warnings on page 1-2. TILT BED REMOVAL NOTE: This procedure requires two people. WARNING • Remove all cargo before raising the bed or servicing the vehicle. If the vehicle is equipped with a prop rod, ensure that it is securely engaged while bed is raised.
Page 39 BODY AND TRIM Tilt Bed 2980 Figure 4-6 Tilt Bed Mounting 2019 Transporter Maintenance and Service Manual Page 4-13...
Page 40: Bed Latch Assembly Removal
Tilt Bed BODY AND TRIM BED LATCH ASSEMBLY REMOVAL NOTE: This procedure requires the aid of an assistant. Park the vehicle and chock the tires. Disconnect the batteries. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-3. Raise bed and secure prop rod (9) in prop rod track (2) (Figure 4-6, Page 4-13). See following WARNING. WARNING •...
Page 41 BODY AND TRIM Tilt Bed 2982 Figure 4-7 Bed Latch Assembly 2019 Transporter Maintenance and Service Manual Page 4-15...
Page 42: Rear Fenders And Tailskirt
Rear Fenders and Tailskirt BODY AND TRIM REAR FENDERS AND TAILSKIRT See General Warnings on page 1-2. 2984 Figure 4-8 Rear Fender and Tailskirt Page 4-16 2019 Transporter Maintenance and Service Manual...
Page 43: Rear Fender And Tailskirt Removal
BODY AND TRIM Rear Fenders and Tailskirt REAR FENDER AND TAILSKIRT REMOVAL Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL and set the park brake. Chock the wheels. Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire(s). See Disconnecting the Batteries –...
Page 44: Rear Triangle Reflector
Rear Triangle Reflector BODY AND TRIM REAR TRIANGLE REFLECTOR Figure 4-9 REAR TRIANGLE REFLECTOR REMOVAL Disable the vehicle. Remove the four rivets (1) and washers (2) (Figure 4-9). Discard the rivets. Remove the rear triangle reflector (3). REAR TRIANGLE REFLECTOR INSTALLATION If the rear triangle reflector has never been installed: 1.1.
Page 45 BODY AND TRIM Rear Triangle Reflector Clean the triangle plate surface area with an Isopropyl Alcohol prep pad (70 percent Isopropyl Alcohol and 30 percent water). Wipe dry before the Isopropyl Alcohol dries. Install the reflective triangle decal (5) on the triangle plate. Make sure to keep proper alignment and remove any air bubbles.
Page 46: Electric Bed Lift
Electric Bed Lift BODY AND TRIM ELECTRIC BED LIFT 2983 Figure 4-10 Electric Bed Lift Page 4-20 2019 Transporter Maintenance and Service Manual...
Page 47: Electric Bed Lift Removal
BODY AND TRIM Electric Bed Lift ELECTRIC BED LIFT REMOVAL NOTE: For vehicles equipped with an electric bed lift. This procedure requires the aid of an assistant. Disconnect the batteries. See Disconnecting the Batteries – Electric Vehicles on page 1-3. Raise the bed.
Page 48: Floor Mat
Floor Mat BODY AND TRIM 2985 Figure 4-11 Electric Bed Mounting FLOOR MAT See General Warnings on page 1-2. FLOOR MAT REMOVAL Remove the brake and accelerator pedals. See Accelerator and Brake Pedal Group, Section 5, Page 5-1. Remove the top edge of the floor mat from the overlapping flange under the dash. Lift the mat from the vehicle.
Page 49: Rear-Facing Seat
BODY AND TRIM Rear-Facing Seat REAR-FACING SEAT 3214 Figure 4-12 Rear-Facing Seat Frame 2019 Transporter Maintenance and Service Manual Page 4-23...
Page 50: Trailer Hitch
Trailer Hitch BODY AND TRIM 3215 Figure 4-13 Rear-Facing Seat Cushions TRAILER HITCH See General Warnings, Section 1, Page 1-2. TRAILER HITCH REMOVAL Remove the tailskirt. See Rear Fender and Tailskirt Removal on page 4-17. Where the hitch is mounted to frame, remove two nuts, lockwashers, flat washers, and bolts. Where the hitch is mounted to hitch brace, remove the nut, lockwasher, flat washer, and bolt.
Page 51: Electrolyte Tray
BODY AND TRIM Electrolyte Tray Tighten hardware to 15 ft·lb (20.3 N·m). Install tailskirt. See Rear Fender and Tailskirt Installation, Section 4, Page 4-17. ELECTROLYTE TRAY See General Warnings, Section 1, Page 1-2. DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area.
Page 52: Electrolyte Tray Removal
Electrolyte Tray BODY AND TRIM Figure 4-14 Electrolyte Trays ELECTROLYTE TRAY REMOVAL Turn the key switch OFF and remove the key. Place the Forward/Reverse switch in NEUTRAL and set the park brake. Chock the wheels. Disconnect the battery set and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-3.
Page 53: Section 5 - Accelerator And Brake Pedal Group
SECTION 5 — ACCELERATOR AND BRAKE PEDAL GROUP DANGER Accelerator and Brake Pedal Group • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. BRAKE PEDAL AND PARK BRAKE See General Warnings on page 1-2. BRAKE PEDAL REMOVAL Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire(s).
Page 54: Brake Pedal Installation
Brake Pedal and Park Brake ACCELERATOR AND BRAKE PEDAL GROUP BRAKE PEDAL INSTALLATION From the top side of the floorboard, insert the brake pedal assembly (1) through the opening in the floor as shown (Figure 5-2, Page 5-3) and install the brake pedal stop bumper (13) (Figure 5-1, Page 5-2) on the brake pedal assembly, but do not tighten the jam nut (12) at this time.
Page 55 ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake 2999 Figure 5-2 Brake Pedal Weldment Through Floor Position and attach brake pedal assembly, mounting blocks (3 and 8), and washers (10) to vehicle frame as shown. Tighten the bolts (11) and nuts to 95 in·lb (10.7 N·m). Tighten the nut (2) on the equalizer rod (1) so that brake pedal free-play is from 1/4 inch to 1/2 inch (6 mm to 13 mm) (Figure 5-3, Page 5-3).
Page 56: Park Brake Removal
Brake Pedal and Park Brake ACCELERATOR AND BRAKE PEDAL GROUP PARK BRAKE REMOVAL Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire(s). See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-3. Place chocks under the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack. Place jack stands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands.
Page 57: Park Brake Installation
ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake PARK BRAKE INSTALLATION From the bottom side of the floorboard, insert the park brake rod (17) through the brake pedal assembly opening. Then install the park brake pawl (35) onto the shaft on the brake pedal assembly (10) and also insert the park brake rod (17) into the park brake pawl (Figure 5-4, Page 5-4).
Page 58: Accelerator Pedal - Electric Vehicles
Accelerator Pedal – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP ACCELERATOR PEDAL – ELECTRIC VEHICLES See General Warnings on page 1-2. 2642 Figure 5-6 Accelerator Pedal – Electric Vehicle with MCOR Page 5-6 2019 Transporter Maintenance and Service Manual...
Page 59: Accelerator Pedal Removal - Electric Vehicles
ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles ACCELERATOR PEDAL REMOVAL – ELECTRIC VEHICLES Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-3. Place chocks under the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack. Place jack stands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands.
Page 60: Pedal Group Adjustment - Electric Vehicles
Pedal Group Adjustment – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP Install the bolt (8) through the pivot rod (6) bearing (9) and spring retainer (11). Secure these parts with the nut (10). Tighten the nut to 50 in·lb (5.5 N·m). Press the brake pedal slightly, and with the park brake ratchet oriented so that the tip of the ratchet is pointed toward the rear of the vehicle, slide the ratchet onto the pivot rod (do not slide the ratchet onto the pivot rod splines).
Page 61 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles bumper upward decreases distance between pedal and floorboard. Adjusting the bumper downward increases distance between pedal and floorboard. Proper brake pedal height is 6 inches (15.2 cm) (Figure 5-9, Page 5-9). 2.4.
Page 62 Pedal Group Adjustment – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP 0.060 inch (1.5 mm) A. Bottom View B. Cutaway Side View 2643 Figure 5-10 Park Brake Ratchet/Pawl Gap Adjustment 4.3. With the park brake unlocked, measure and note the distance from the top of the accelerator pedal to the floorboard, then lock the park brake (Figure 5-11, Page 5-10).
Page 63 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles closest to the floorboard. Press the accelerator pedal until the end of the tool rests against the floorboard; pedal height should be 5-5/8 inches (14.3 cm). Use a rubber strap to hold pedal in position against the floorboard and then tighten nut to 26 ft·lb (35.3 N·m) (Figure 5-15, Page 5-11).
Page 64 Pedal Group Adjustment – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP Pagination Page Page 5-12 2019 Transporter Maintenance and Service Manual...
Page 65: Section 6 - Brake System
SECTION 6 — BRAKE SYSTEM DANGER Brake System • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. Asbestos Dust Warning • Some aftermarket brake shoes contain asbestos fiber, and asbestos dust is created when these brake mechanisms are handled.
Page 66 Brake Shoe Removal BRAKE SYSTEM BRAKE DRUM TWO BRAKE SHOE RETAINER PIN HEADS AXLE TUBE 1/2 INCH X 5/8 INCH COLD CHISEL 2814 2834a Figure 6-1 Loosen Equalizer Nut Figure 6-2 Shoe Retainer Pins 4.2. Insert a 1/2 inch x 5/8 inch cold chisel (1) under the head (2) of each pin and shear them off as illustrated (Figure 6-2, Page 6-2).
Page 67: Brake Assembly Cleaning
BRAKE SYSTEM Brake Assembly Cleaning 2824 2825 Figure 6-3 Rotate Clip Retainer Figure 6-4 Remove Shoes BRAKE ASSEMBLY CLEANING See General Warnings on page 1-2. See also Asbestos Dust Warning on page 6-1. Carefully clean the brake backing plate and all mechanical components. Remove the rubber boot from backing plate and wipe with a clean damp cloth.
Page 68 Brake Assembly Cleaning BRAKE SYSTEM Use a small brush to carefully apply a light coat of white lithium NLGI #2 grease (Dow Corning ® BR2-Plus or equivalent) on each of the six raised bosses on brake backing plate (Figure 6-6). See preceding WARNING. 2817 Figure 6-6 Lubricate Raised Bosses Use a small brush to carefully apply a light coat of white lithium NLGI #2 grease (Dow Corning BR2-Plus or...
Page 69 BRAKE SYSTEM Brake Assembly Cleaning Use a small brush to carefully apply a light coat of white lithium NLGI #2 grease (Dow Corning BR2-Plus or equivalent) to the brake actuator assembly as shown (Figure 6-8, Page 6-5). See preceding WARNING. 2799 Figure 6-8 Lubricate Actuator 2019 Transporter Maintenance and Service Manual...
Page 70: Brake Shoe Installation
Brake Shoe Installation BRAKE SYSTEM BRAKE SHOE INSTALLATION See General Warnings on page 1-2. See also Asbestos Dust Warning on page 6-1. NOTE: Components of the front wheel brake assembly are identical to the rear wheel manually-adjusted brake assembly. The front brake assembly is rotated 90° (when compared to the rear brake assembly) so the adjusting bolt on each assembly is oriented to the rear of the vehicle rather than at the top of the assembly (Figure 6-21, Page 6-15).
Page 71: Brake Adjustment
BRAKE SYSTEM Brake Adjustment 2808 2800 Figure 6-11 Insert Shoes Figure 6-12 Position Shoes CAUTION • Clean any residual oil from the exposed end of the axle shaft and from the oil seal area prior to installing the axle shaft. For electric vehicles: Install the axle shaft.
Page 72: Brake Cluster Adjustment
Figure 6-16 Front Brake Adjustment Bolt Use a torque wrench and a 7 mm 8–point socket or Club Car brake adjustment tool to turn the brake adjustment bolt (5) on each brake clockwise until it is tightened to 15 ft·lb (20.3 N·m) then back off 5 clicks. See following...
Page 73 BRAKE SYSTEM Brake Adjustment 2806 Figure 6-17 Front Manually Adjusted Brake Assembly 2019 Transporter Maintenance and Service Manual Page 6-9...
Page 74: Brake Cable Equalization
Brake Adjustment BRAKE SYSTEM TYPICAL 4 PLACES TYPICAL 4 PLACES 2903 Figure 6-18 Rear Manually-Adjusted Brake Assembly BRAKE CABLE EQUALIZATION Set park brake in the third tooth of the ratchet. Place a wedge between the park brake pedal and brake pedal to prevent the park brake from disengaging while equalizing the brake cables (Figure 6-19, Page 6-11).
Page 75: Final Brake Cluster Adjustment
BRAKE SYSTEM Brake Adjustment 2809 Figure 6-19 Set Park Brake and Insert Wedge Equalize the brake cables. 2.1. Tighten the nylon lock nut (6) on the front equalizer rod (2) to 35 in·lb (4 N·m) (Figure 6-14, Page 6-8). 2.2. Tighten the jam nut (5) on the rear equalizer rod (2) clockwise to 35 in·lb (4 N·m) (Figure 6-13, Page 6-8).
Page 76: Brake Cluster Removal And Installation
Brake Cluster Removal and Installation BRAKE SYSTEM Test drive vehicle. Be sure the brakes function properly. When brake pedal is fully pressed under moderate pressure, it should not go more than halfway to floor, and the vehicle should come to a smooth, straight stop. If the brake pedal goes more than halfway to the floor, or if the vehicle swerves or fails to stop, check pedal group adjustment, and readjust cable tension and brakes.
Page 77 BRAKE SYSTEM Brake Cluster Removal and Installation TYPICAL 4 PLACES 2810 Figure 6-20 Front Spindle Assembly 2019 Transporter Maintenance and Service Manual Page 6-13...
Page 78: Rear Brake Cluster Removal
Brake Cluster Removal and Installation BRAKE SYSTEM REAR BRAKE CLUSTER REMOVAL Place chocks at the front wheels, loosen the lug nuts on the rear wheels and lift the rear of the vehicle with a chain hoist or floor jack. Place jack stands under the axle tubes to support the vehicle. Release park brake and loosen equalizer retaining nuts (1 and 5) on equalizer rod (2) to slightly loosen brake cable (Figure 6-13, Page 6-8).
Page 79: Front Brake Cables
BRAKE SYSTEM Front Brake Cables FRONT BRAKE CABLES See General Warnings on page 1-2. See also Asbestos Dust Warning on page 6-1. 3189 Figure 6-21 Front Brake Cables and Equalizer 2019 Transporter Maintenance and Service Manual Page 6-15...
Page 80: Front Brake Cable Removal
Front Brake Cables BRAKE SYSTEM FRONT BRAKE CABLE REMOVAL Remove bow-tie pin (9) and clevis pin (6) from brake lever arm on front brake cluster (Figure 6-21, Page 6-15). Remove E-clip (7) from brake cable housing at the front spindle bracket and remove cable (8 or 18) from spindle. Remove bow-tie pin (9), clevis pin (6), and E-clip (7) from brake cable (8 or 18) at equalizer (2).
Page 81: Rear Brake Cables
BRAKE SYSTEM Rear Brake Cables REAR BRAKE CABLES 3191 Figure 6-23 Rear Brake Cables and Equalizer 2019 Transporter Maintenance and Service Manual Page 6-17...
Page 82: Rear Brake Cable Removal
Rear Brake Cables BRAKE SYSTEM REAR BRAKE CABLE REMOVAL Chock wheels to keep vehicle from unintentionally moving. Release park brake if latched and loosen equalizer retaining nuts (13 and 14) on equalizer rod (2) to slightly loosen brake cables (7) (Figure 6-23, Page 6-17). Rotate brake cables (7) upward and pull ends through holes in top of equalizer (3).
Page 83: Emergency Brake System
BRAKE SYSTEM Emergency Brake System EMERGENCY BRAKE SYSTEM EMERGENCY BRAKE REMOVAL Chock the wheels to prevent the vehicle from rolling. Release the emergency brake. Disconnect emergency brake cables (1) at rear wheels. 3.1. Remove locknut (2), washers (3), and shoulder bolt (4) securing each cable (1) to brake lever arm (Figure 6-24, Page 6-19).
Page 84: Emergency Brake Installation
Emergency Brake System BRAKE SYSTEM Figure 6-26 Emergency Brake Removal EMERGENCY BRAKE INSTALLATION Installation is the reverse of removal. See also for more info. Tighten the emergency brake locknuts (6) to 72 in-lb (8 N·m) (Figure 6-26, Page 6-20). Tighten the brake lever arm locknuts (2) to 72 in-lb (8 N·m) (Figure 6-24, Page 6-19).
Page 85 BRAKE SYSTEM Emergency Brake System 3213 Figure 6-27 Adjustment Knob Set Screw Place vehicle on a level surface and release the emergency brake. Loosen the adjustment knob set screw with an Allen wrench (Figure 6-27, Page 6-21). Turn adjustment knob clockwise to tighten cables. Tighten cables until a force of 133 to 138 N (30 to 31 lbf) is required to pull the handle up to the engaged position.
Page 86 Emergency Brake System BRAKE SYSTEM Pagination Page Page 6-22 2019 Transporter Maintenance and Service Manual...
Page 87: Section 7 - Steering And Front Suspension
SECTION 7 — STEERING AND FRONT SUSPENSION DANGER Steering and Front Suspension • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION Steering is controlled through a rack and pinion steering assembly that is connected by a steering column to a steering wheel.
Page 88: Steering Wheel Installation
Steering Wheel STEERING AND FRONT SUSPENSION 2862 1500-18300-10253 Figure 7-1 Steering Wheel 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 splines and taper before installing the steering wheel.
Page 89: Steering Column
STEERING AND FRONT SUSPENSION Steering Column STEERING COLUMN See General Warnings on page 1-2. 2609 Figure 7-3 Steering Column 2019 Transporter Maintenance and Service Manual Page 7-3...
Page 90: Steering Column Removal
Steering Column STEERING AND FRONT SUSPENSION STEERING COLUMN REMOVAL Remove the steering wheel as previously instructed. Remove cowl. See Cowl Removal, Section 4, Page 4-4. Remove the upper bolt (2) and lock washer (3) from the universal joint (Figure 7-3, Page 7-3). Remove the nuts (9), bolts (8 and 10), and washers (7 and 11) from the steering column mount (4 and 5) (Figure 7-3, Page 7-3).
Page 91: Steering Column Installation
STEERING AND FRONT SUSPENSION Steering Column 1. Step 1 1. Step 1 2. Step 2 2. Step 2 3. Step 3 3. Step 3 1500-18200-10255 1500-18200-10256 Figure 7-4 Steering Shaft – Bottom End Figure 7-5 Steering Shaft – Top End STEERING COLUMN INSTALLATION Install boot (12).
Page 92: Steering Adjustment
Steering Adjustment STEERING AND FRONT SUSPENSION STEERING ADJUSTMENT See General Warnings on page 1-2. Turn the steering wheel all the way to the right. Note the distance between the passenger side spindle stop (2) and passenger side A-plate (3) (Figure 7-6, Page 7-8). The internal stop on the rack must reach its limit of travel against rack and pinion housing at exactly the same time the spindle stops against the passenger side A-plate (with vehicle wheels turned to the right).
Page 93: Rack And Pinion
STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION See General Warnings on page 1-2. CAUTION • Front impacts that bend tie rods and/or drag links can possibly damage internal steering gear components. See Rack and Pinion Inspection on page 7-7. The manufacturer recommends inspecting the rack and pinion and replacing if damaged.
Page 94: Rack And Pinion Disassembly
Rack and Pinion STEERING AND FRONT SUSPENSION 1838 Figure 7-6 Adjust Steering Alignment RACK AND PINION DISASSEMBLY CAUTION • The ball joint (23) (Figure 7-10, Page 7-10) has left-hand threads. Remove ball joint from the spindle and inspect it for excessive wear. Remove the drag link (28) (Figure 7-10, Page 7-10).
Page 95 STEERING AND FRONT SUSPENSION Rack and Pinion 1. Press Ram 2. Pinion Gear 3. Bearing 1500-18400-10259 1500-18400-10260 Figure 7-7 Remove Pinion from Housing Figure 7-8 Remove Bearing from Pinion If necessary, remove the dust seal (12). See following NOTE. NOTE: If the dust seal (12) is removed, replace with a new one. Use snap ring pliers to remove the internal snap ring (11) (Figure 7-10, Page 7-10).
Page 96: Rack And Pinion Assembly
Rack and Pinion STEERING AND FRONT SUSPENSION 1839 Figure 7-10 Steering Gear – Maintenance-Free Ball Joints RACK AND PINION ASSEMBLY Install a new tab washer (4) and an inner ball joint (3) (Figure 7-9, Page 7-9). Install the ball joint onto the rack by securing the rack in a vise using wood blocks between the rack and the jaws of the vise to protect the rack from damage.
Page 97 STEERING AND FRONT SUSPENSION Rack and Pinion Apply a light coating of EP grease to the teeth of the rack (17), then slide the rack through the bushing (5) and housing (6). Install the stop washer (18) and retaining ring (19) to the end of the rack (Figure 7-10, Page 7-10). CAUTION •...
Page 98 Rack and Pinion STEERING AND FRONT SUSPENSION 1500-18400-10265 Figure 7-13 Rack and Pinion Resistance Install the internal snap ring (11) (Figure 7-10, Page 7-10). Using an appropriate size deep well socket (1) to apply pressure evenly, press in a new dust seal (2) (Figure 7-11, Page 7-11).
Page 99: Rack And Pinion Installation
STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION INSTALLATION Position the steering gear box assembly on the shock and gear support and install the bolts (30), washers (31), and nuts (32). Do not tighten the mounting bolts (Figure 7-10, Page 7-10). For ease of assembly and to prevent corrosion, apply a light coat of anti-seize and lubricating compound to the splined end of the steering column shaft.
Page 100: Tie Rod And Drag Link
Tie Rod and Drag Link STEERING AND FRONT SUSPENSION TIE ROD AND DRAG LINK See General Warnings on page 1-2. TIE ROD AND DRAG LINK REMOVAL Using locking pliers to hold tie rod and drag link, loosen jam nuts (7 and 12) on tie rod ball joints (Figure 7-18, Page 7-18) and loosen jam nuts (27 and 29) on the drag link (Figure 7-10, Page 7-10).
Page 101: Front Suspension
STEERING AND FRONT SUSPENSION Front Suspension FRONT SUSPENSION See General Warnings on page 1-2. LUBRICATION Two grease fittings (one in each spindle housing) are provided. Lubricate these fittings at the recommended interval with the proper lubricant. See Periodic Lubrication Schedules, Section 10, Page 10-6. WHEEL ALIGNMENT Wheel alignment is limited to equalizing the camber angle of each front wheel and adjusting toe-in of the front wheels.
Page 102 Front Suspension STEERING AND FRONT SUSPENSION Tighten the hex nut (8) on the adjustment eccentric (7) to 23 ft·lb (31 N·m) (Figure 7-19, Page 7-19). See also Figure 7-15, Page 7-15. 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.
Page 103: Front Suspension Components
STEERING AND FRONT SUSPENSION Front Suspension Components FRONT SUSPENSION COMPONENTS See General Warnings on page 1-2. LEAF SPRING REMOVAL Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire(s). See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-3. Remove both front wheels.
Page 104 Front Suspension Components STEERING AND FRONT SUSPENSION 2610 Figure 7-18 Front Suspension – Upper Portion Page 7-18 2019 Transporter Maintenance and Service Manual...
Page 105 STEERING AND FRONT SUSPENSION Front Suspension Components 2611 Figure 7-19 Front Suspension – Lower Portion 2019 Transporter Maintenance and Service Manual Page 7-19...
Page 106: Kingpin And Steering Spindle Installation
Front Suspension Components STEERING AND FRONT SUSPENSION KINGPIN AND STEERING SPINDLE INSTALLATION Inspect all parts and replace them as necessary. Install the kingpin (26) over the leaf spring eye. Insert the bolt (25) and install the nut (14) (Figure 7-19, Page 7-19).
Page 107: Front Wheel Bearings And Hubs
STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs FRONT WHEEL BEARINGS AND HUBS See General Warnings on page 1-2. FRONT WHEEL FREE PLAY INSPECTION Raise the front of the vehicle. Using your hands, attempt to rock the wheel and hub assembly back and forth on the spindle. If there is any observable movement of the wheel and hub on the spindle, remove dust cap (1) and cotter pin (2) and then tighten the spindle nut (3) until the bearing (5) fully seats in the bearing race (7) (Figure 7-20, Page 7-21).
Page 108: Front Hub And Wheel Bearings Installation
Front Wheel Bearings and Hubs STEERING AND FRONT SUSPENSION FRONT HUB AND WHEEL BEARINGS INSTALLATION Pack the wheel bearings (5) and hub cavities, and lubricate cups (7) with wheel bearing grease or chassis lube. Make sure the grease is forced between the rollers (Figure 7-20, Page 7-21). If bearing cups (7) were removed, press new ones in squarely against stops in the hub (Figure 7-20, Page 7-21).
Page 109: Section 8 - Wheels And Tires
• See General Warnings on page 1-2. GENERAL INFORMATION NOTE: Use only Club Car approved tires when replacing tires. Maximum tire life and good vehicle handling qualities are directly related to proper wheel and tire care. • Keep tires properly inflated. See Vehicle Specifications on page 2-1.
Page 110: Tires
Tires WHEELS AND TIRES TIRES See General Warnings on page 1-2. 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. See Wheel Removal on page 8-1. Remove the valve cap and valve core and allow air to escape from the tire.
Page 111: Tire Installation
WHEELS AND TIRES Tires NOTE: An air leak could be due to a punctured casing, faulty valve core, improperly seated valve stem, or improperly seated tire bead. Small holes in the casing can be plugged using a standard automotive tubeless tire repair kit available at auto supply stores.
Page 112 Tires WHEELS AND TIRES Figure 8-2 Inflate Tire Page 8-4 2019 Transporter Maintenance and Service Manual...
Page 113: Section 9 - Rear Suspension
SECTION 9 — REAR SUSPENSION DANGER Rear Suspension • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. 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 114: Multi-Leaf Springs
Multi-Leaf Springs REAR SUSPENSION NOTE: Tighten 3/8 hex nut at shock absorber until shock absorber cushions are approximately the same diameter as the retainers. Do not over tighten. On the upper and lower shock absorber mounting stems, tighten the nut (1) until the rubber bushing (3) expands to the size of the cup washer (4).
Page 115: Multi-Leaf Spring Installation
REAR SUSPENSION Multi-Leaf Springs 2600-30000-10369 1400-18100-10243 Figure 9-2 Support Vehicle on Jack Stands Figure 9-3 Disconnect Brake Cable MULTI-LEAF SPRING INSTALLATION NOTE: Tighten bolt (11) after clamp from brake cable has been positioned between nut and frame component. Install the bushings and spacers in the spring eyes. See following CAUTION. CAUTION •...
Page 116 Multi-Leaf Springs REAR SUSPENSION 2987 Figure 9-4 Rear Suspension Assembly and Mounting Page 9-4 2019 Transporter Maintenance and Service Manual...
Page 117: Section 10 - Periodic Maintenance
Use the following checklist, in conjunction with the Pre-Operation and Daily Safety Checklist, as a guide to inspect the vehicle and check daily for proper operation. Any problems should be corrected by a Club Car distributor/dealer or a trained technician.
Page 118: Maintenance
Club Car vehicles operate at reduced speed in reverse. When the pedal is released, it should return to the original position and the motor should rotate freely or go into motor braking mode. See Pedal Up Motor Braking below.
Page 119: Periodic Service Schedules
PERIODIC MAINTENANCE Periodic Service Schedules WARNING • If any problems are found during scheduled inspection or service, do not operate the vehicle until repairs are made. Failure to make necessary repairs can result in fire, property damage, serious personal injury, or death. •...
Page 120 Periodic Service Schedules PERIODIC MAINTENANCE PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE See Pre-Operation and Daily Safety Pre-Operation and Daily Safety Checklist Checklist on page 10-1. Daily service by owner Performance Inspection See Performance Inspection on page 10-1. Batteries Charge batteries (after each daily use only). Batteries (For vehicles NOT equipped with the Check electrolyte level.
Page 121 PERIODIC MAINTENANCE Periodic Service Schedules PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Manually check battery electrolyte levels of Batteries (For vehicles equipped with the all cells to verify correct valve operation. See SPWS) page 14-8. Annual service by trained technician only If batteries are not performing as expected, (or every 100 hours of operation, whichever Batteries...
Page 122: Periodic Lubrication Schedules
Periodic Lubrication Schedules PERIODIC MAINTENANCE PERIODIC LUBRICATION SCHEDULES PERIODIC LUBRICATION SCHEDULE LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Brake pedal shaft bearings Dry Moly Lube Brake linkage and pivots Dry Moly Lube Semiannually by owner or trained technician (or every 50 Accelerator pivot rod supports Dry Moly Lube hours of operation, whichever...
Page 123: Section 11 - Controller Diagnostic Tool (Cdt)
SECTION 11 — CONTROLLER DIAGNOSTIC TOOL (CDT) DANGER Controller Diagnostic Tool (CDT) • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. NOTE: The information presented in this section addresses the following: • The Controller Diagnostic Tool (CDT) handheld programmer which replaced the IQDM series 2 handset. •...
Page 124: General Information
General Information CONTROLLER DIAGNOSTIC TOOL (CDT) GENERAL INFORMATION The CDT is used to adjust and save parameter settings of the controller, monitor real-time data, and perform diagnostics and troubleshooting of the electric vehicle. FEATURES • Batteries: Two AA batteries provide power for the CDT’s real-time clock and they allow for use of the CDT when not connected to a vehicle.
Page 125: Introductory Display
CONTROLLER DIAGNOSTIC TOOL (CDT) Plugging the CDT into the Vehicle Connect one end of the cable to the port located on the bottom of the CDT. Connect the cable adaptor to the CDT cable. Find the communication port on the vehicle (Figure 11-2, Page 11-2). Remove the dust cap from the communication port.
Page 126: Quick Reference Guide - Iq Plus With Quiq Charger
Quick Reference Guide – IQ Plus with Quiq Charger CONTROLLER DIAGNOSTIC TOOL (CDT) QUICK REFERENCE GUIDE – IQ PLUS WITH QUIQ CHARGER OPERATION: Change screen contrast for better viewing by selecting the following: HPP Settings, Backlight Preset Favorites: Select a frequently viewed screen, press “Add to” softkey, highlight “Favorites”, press “Select” softkey. CONTROLLER FAULTS: Anti Tamper: If car not equipped with Visage, make sure Control Mode Main Weld: Replace solenoid, if it doesn’t correct fault of car running at...
Page 127: System Info
CONTROLLER DIAGNOSTIC TOOL (CDT) System Info SYSTEM INFO The System Info menu is accessed by using the arrow keys to highlight System Info and pressing the Select softkey to activate the menu. The System Info selection displays information pertaining to the controller. The information provided from this menu selection includes: MODEL NUMBER Displays the model number of the controller.
Page 128 A vehicle programmed for speed setting 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 information on this feature, contact your local Club Car distributor or dealer. M1/M2 Fast Accel M1/M2 fast accel (fast acceleration) is an option that can be enabled or disabled.
Page 129 CONTROLLER DIAGNOSTIC TOOL (CDT) Parameters Change the settings of the M1/M2 Pedal Up by pressing “+” or “–” on the change value button. M1/M2 PEDAL UP SETTING MODE OPERATION DESCRIPTION Pedal up motor braking is disabled Mild pedal up Mild pedal up motor braking Aggressive pedal up Aggressive pedal up motor braking M1/M2 Speed Cal...
Page 130 Parameters CONTROLLER DIAGNOSTIC TOOL (CDT) 5.8 mph (9.3 km/h) 9.8 mph (15.8 km/h) 12.8 mph (20.6 km/h) 14.8 mph (23.8 km/h) 5.7 mph (9.2 km/h) 9.7 mph (15.6 km/h) 12.7 mph (20.4 km/h) 14.7 mph (23.7 km/h) 5.6 mph (9.0 km/h) 9.6 mph (15.4 km/h) 12.6 mph (20.3 km/h) 14.6 mph (23.5 km/h)
Page 131 Once activated, Mode 2 settings can be programmed using the same procedures as Mode 1 settings. This allows the vehicle to be customized to perform according to which mode it is operated in. For more information on this feature, contact your local Club Car distributor or dealer. To activate Mode 2: Enter Code A, Code B, and Code C.
Page 132 Parameters CONTROLLER DIAGNOSTIC TOOL (CDT) ASCII NUMBER ASCII CHARACTER ASCII NUMBER ASCII CHARACTER Vehicle Date of Manufacture Four digit number programmed by vehicle manufacturer. Example: 1401 represents Model Year 2014, week 1. Vehicle S/N Six digit number programmed by vehicle manufacturer. Vehicle Decal Decal number ranging from 0 to 999 and programmed by vehicle manufacturer.
Page 133 CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu MONITOR MENU The Monitor menu is accessed by using the arrow keys to highlight Monitor and pressing the Select softkey to activate the menu. All information in the Monitor menu is updated in real time, allowing the trained technician to troubleshoot the vehicle by monitoring the handset as the key switch is cycled, Forward/Reverse switch is activated, etc.
Page 134 Mode 2. If repeated attempts are unsuccessful, the speed controller will permanently lock out access to Mode 2. In the event that Mode 2 is locked out, the controller must be removed and shipped to Club Car before Mode 2 can be activated.
Page 135 CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu CIR BRKR OPEN # Displays the number of times the CIR BRKR OPEN fault has been detected. See Fault Descriptions on page 11-20. THRTL FAULT # Displays the number of times the THRTL fault has been detected. See Fault Descriptions on page 11-20. UNDERVOLTAGE # Displays the number of times the UNDERVOLTAGE fault has been detected.
Page 136 Monitor Menu CONTROLLER DIAGNOSTIC TOOL (CDT) RELAY DNC # Displays the number of times the RELAY DNC fault has been detected (Did not close). See Fault Descriptions on page 11-20. CURRENT SENSE # Displays the number of times the CURRENT SENSE fault has been detected. See Fault Descriptions on page 11-20. M-SHORTED # Displays the number of times the M-SHORTED fault has been detected.
Page 137 CONTROLLER DIAGNOSTIC TOOL (CDT) Monitor Menu CHARGER INHIBIT Displays charger connection. When the charger is connected and the controller does not drive (inhibited), the handset indicates ON. When the charger is not connected and the controller is allowed to drive, the handset indicates OFF. LED DRIVER Displays the present state of pin 11 in the controller 16-pin connector that operates the charge indicator light on the dash.
Page 138: Amp Hours Display
Monitor Menu CONTROLLER DIAGNOSTIC TOOL (CDT) Storage Charges Displays the number of storage charge cycles. AMP HOURS DISPLAY Signed Battery Current While driving the vehicle, this displays either the current being pulled out of the batteries or the current being returned to the batteries during regenerative motor braking.
Page 139: Diagnostics Menu
CONTROLLER DIAGNOSTIC TOOL (CDT) Diagnostics Menu DIAGNOSTICS MENU CAUTION • A failed motor will damage the controller. Always inspect the motor before replacing the controller. See External Motor Testing, Section 16, Page 16-1. NOTE: The software is subject to frequent updates, and this manual may span many versions. Be aware that some faults listed in this manual may not display in the CDT, indicating older software.
Page 140 Diagnostics Menu CONTROLLER DIAGNOSTIC TOOL (CDT) Causes of Faults Some common causes of faults are • Loose, broken, or disconnected wires or connectors • Failed components • Improper adjustment or installation of electrical or mechanical components (examples: brake adjustment, improper MCOR installation) •...
Page 141: Fault Recovery
CONTROLLER DIAGNOSTIC TOOL (CDT) Diagnostics 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 142: Fault Descriptions
Fault Descriptions CONTROLLER DIAGNOSTIC TOOL (CDT) FAULT DESCRIPTIONS The following faults can be detected by the IQ Plus controller and seen under both the Monitor Menu and Diagnostics Menu: 01 THROTTLE FAULT 1 If the MCOR (Motor Controller Output Regulator) voltage is less than 0.20 volts or greater than 4.80 volts, the controller detects a throttle fault.
Page 143: 12 Main Dropout
CONTROLLER DIAGNOSTIC TOOL (CDT) Fault Descriptions 12 MAIN DROPOUT If the controller detects that the solenoid contacts have opened while the vehicle is in operation, a main dropout fault is detected. 13 MOTOR STALL If the motor current is high and there is no movement of the vehicle wheels for a short period of time, a motor stall is detected by the speed controller.
Page 144: 25 Incorrect Password
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 Mode 2. See also Password Tries (OEM Access Level Only) on page 11-12.
Page 145: Main Cont Dnc
CONTROLLER DIAGNOSTIC TOOL (CDT) Fault Descriptions MAIN CONT DNC The main cont dnc (main contactor (solenoid) did not close) fault is detected when the speed controller has sent voltage to the solenoid activating coil but the solenoid contacts are not closed. MAIN COIL FAULT If the speed controller determines that the solenoid is not closing as a result of a solenoid coil failure, a main coil fault is detected.
Page 146: Programming
Programming CONTROLLER DIAGNOSTIC TOOL (CDT) PROGRAMMING The Programming menu is accessed by using the arrow keys to highlight Programming and pressing the Select softkey to activate the menu. The Programming menu selection allows the user to save and restore parameter settings files (.cpf files). These files contain controller information and are saved to the internal memory or SD card.
Page 147: Hhp Settings
CONTROLLER DIAGNOSTIC TOOL (CDT) HHP Settings HHP SETTINGS The HHP Settings menu is accessed by using the arrow keys to highlight HHP Settings and pressing the Select softkey to activate the menu. The HHP Settings menu selection allows the user to adjust the appearance of the screen displays, adjust several aspects of the handheld programmer’s functionality, and displays information pertaining to the handset.
Page 148: Plot & Log
Plot & Log CONTROLLER DIAGNOSTIC TOOL (CDT) MENU ITEM DESCRIPTIONS Remember Last View When set to On, when you select a menu from the Main Menu screen, you will be returned to the screen you were on before you last exited that menu. When set to Off, each time you select a menu from the Main Menu screen, you will go to the selected root menu.
Page 149: Cdt Troubleshooting
CONTROLLER DIAGNOSTIC TOOL (CDT) CDT Troubleshooting CDT 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 150: Connection Tests
Connection Tests CONTROLLER DIAGNOSTIC TOOL (CDT) TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Disconnect the CDT cord from the vehicle. Handset malfunction Wait a few seconds and reconnect the handset to the vehicle Vehicle batteries – loose terminals or corrosion Section 14 —...
Page 151 CONTROLLER DIAGNOSTIC TOOL (CDT) Connection Tests 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 152 Connection Tests CONTROLLER DIAGNOSTIC TOOL (CDT) Figure 11-3 Disconnect Four-pin Connector. Page 11-30 2019 Transporter Maintenance and Service Manual...
Page 153: Section 12 - Electrical System Troubleshooting
SECTION 12 — ELECTRICAL SYSTEM TROUBLESHOOTING DANGER Electrical System Troubleshooting • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION The IQ Plus vehicle uses a 48-volt electrical system with a shunt-wound, 3.7 hp motor that is powered by eight 6-Volt, lead-acid batteries and charged by a high-frequency charger.
Page 154 Contact your Club Car dealer/distributor to inquire about this programmable 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 155 General Information ELECTRICAL SYSTEM TROUBLESHOOTING Pagination Page Page 12-3 2019 Transporter Maintenance and Service Manual...
Page 156: Sonic Weld, Diode, And 10K Ohm Resistor Locations
Sonic Weld, Diode, and 10k Ohm Resistor Locations ELECTRICAL SYSTEM TROUBLESHOOTING SONIC WELD, DIODE, AND 10K OHM RESISTOR LOCATIONS 3119 Figure 12-1 Sonic Weld, Diode and 10k Ohm Resistor Locations (Approximate) – CA300 with ERIC Charging Page 12-4 2019 Transporter Maintenance and Service Manual...
Page 157: Troubleshooting
TROUBLESHOOTING THE VEHICLE WITH THE CDT Club Car recommends the use of the CDT handset for troubleshooting vehicles equipped with the IQ Plus electrical system. Troubleshooting Guide 1 is to be used in conjunction with the CDT handset. Refer to the CDT Owner’s Manual for operating instructions.
Page 158 Troubleshooting ELECTRICAL SYSTEM TROUBLESHOOTING TROUBLESHOOTING GUIDE 1 The following troubleshooting guide is intended for use with an CDT handset. For CDT operating instructions, refer to the CDT Owner’s Manual. See following NOTE. NOTE: Before troubleshooting the vehicle, check the diagnostic history from the Special Diagnostics Menu. Note any fault codes.
Page 159 ELECTRICAL SYSTEM TROUBLESHOOTING Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Speed controller logic malfunction Disconnect the batteries and allow the speed controller capacitors to discharge. See WARNING “To avoid unintentionally starting...” in See General Warnings Failed controller FET (that powers up Monitor Menu –...
Page 160 Troubleshooting ELECTRICAL SYSTEM TROUBLESHOOTING TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected motor field coil wires at motor or speed controller or Repair and/or connect the field coil wires broken wire Diagnostic Menu – FIELD MISSING fault code Failure of the motor field windings Section 16 —...
Page 161: Troubleshooting Guide 1
ELECTRICAL SYSTEM TROUBLESHOOTING Troubleshooting TROUBLESHOOTING GUIDE 2 TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Batteries discharged Charge batteries Check vehicle wiring. See Wiring Diagrams Improper or poor battery connections beginning on page Battery charger is connected to the vehicle – Disconnect the battery charger from the vehicle Solenoid lockout feature has disabled the vehicle Check for loose or disconnected wires at key...
Page 162 Troubleshooting ELECTRICAL SYSTEM TROUBLESHOOTING TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Test Procedure 13 – Motor Speed Sensor on page Speed sensor disconnected or failed 12-26 To change the programmed top speed of the Incorrect speed setting vehicle, an CDT handset must be used Check vehicle wiring.
Page 163: Test Procedures
ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures TEST PROCEDURES Using the following procedures, the entire IQ Plus electrical system can be tested without major disassembly of the vehicle. See following WARNING. 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 164 Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING 11 – Charger Interlock 12 – MCOR Voltage 13 – Motor Speed Sensor 14 – A1 and A2 Motor Voltage 15 – 24-Pin Connector 16 – Reverse Buzzer 17 – Walk Away Braking Relay 18 – Charge Indicator Light 19 –...
Page 165 ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures (Viewed from driver side of vehicle) 1. RED probe to battery no. 1 (+). 2. BLACK probe to battery no. 6 (-). 3072 Figure 12-2 Battery Voltage Test – 500/550/700 2019 Transporter Maintenance and Service Manual Page 12-13...
Page 166 Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING TEST PROCEDURE 2 – 48-Volt Battery Pack Voltage Under Load See General Warnings on page 1-2. NOTE: This is a voltage test. If necessary, see Testing Basics on page 12-11. 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.
Page 167 ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures A fully charged set of batteries in good condition should read between 47 and 49 volts while under load. A reading of 32 to 42 volts indicates discharged or failed batteries. Each battery should be checked with a multimeter while under load.
Page 168 Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING TEST PROCEDURE 4 – Fuses See General Warnings on page 1-2. WARNING • Failure to use properly rated fuse can result in a fire hazard. NOTE: These vehicles predominately use a combination of ATC-style and ATM-style blade fuses. A single AGC-style glass fuse is used for the charger interlock circuit.
Page 169 ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures – For one of the 15-amp ATC fuses, check Run/Tow switch to make sure it is in RUN position. – Check if 12 gauge red wire is coming off large post on solenoid. 1-amp AGC Glass Fuse Only: With the Run/Tow switch in the RUN position: 4.1.
Page 170 Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING If there is 48 volts, do the following: Make sure that the green and tan wires are securely connected to the circuit breaker. Make sure that the 24 pin connector has no corrosion. Make sure that the 24 pin connector is securely connected to the controller. Make sure that the number 3 pin of the 24 pin connector is seated correctly into the 24 pin connector.
Page 171 ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. VOM Black Lead 2. VOM Red Lead 3. Wiring Diagram Symbol with Diode Stripe Orientation 4.
Page 172 Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING TEST PROCEDURE 7 – Key Switch and MCOR Limit Switch Circuit See General Warnings on page 1-2. NOTE: This is a voltage test. The MCOR provides FOOT INPUT to the controller. The key switch provides KEY INPUT to the controller. Key Switch and MCOR Limit Switch Circuit Test with the CDT Handset Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack.
Page 173 ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures 4.1. Locate and connect an insulation-piercing probe to the pin 1 tan wire in the 24-pin connector. 4.2. With the key switch in the OFF position and the accelerator pedal at rest, the tan wire should show zero (0) volts.
Page 174 Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING 4.1. Access the Monitor menu and select REVERSE INPUT by using the SCROLL DISPLAY buttons. The CDT should indicate OFF when the Forward/Reverse switch is in the NEUTRAL or FORWARD position. 4.2. Place the Forward/Reverse switch in the REVERSE position. The CDT should indicate that REVERSE INPUT is ON.
Page 175 See General Warnings on page 1-2. NOTE: Unlike other controllers used by Club Car, the pre-charge resistor is internal to the IQ Plus controller. 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 176 Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING Insert the onboard charger AC plug into an AC outlet. In a few seconds, the CDT should indicate ON and the vehicle can no longer be driven. If not, check the KEY, FORWARD, REVERSE and FOOT INPUTS to the controller. –...
Page 177 ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures MCOR Voltage Test with the CDT Handset 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. See WARNING “Lift only one end...”...
Page 178 Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING at the MCOR. The reading should be zero (0) volts with the pedal up. Slowly press the accelerator pedal and note the readings on the multimeter. As the pedal is pressed, the reading should increase until it reaches approximately 4.65 volts when the pedal is fully pressed.
Page 179 ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures Turn the key switch to the OFF position and place the Forward/Reverse switch in the NEUTRAL position. With batteries connected, disconnect the three-pin connector at the motor speed sensor. Check voltage at black/white wire: 3.1. Set a multimeter to 200 volts DC.
Page 180 Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING Figure 12-9 Test 13: Speed Sensor Red Wire Check voltage at the light green wire: 5.1. Set a multimeter to 20 volts DC. Place the black (–) probe on the battery no. 8 negative post and place the red (+) probe on the light green wire female terminal in the three-pin connector at the motor speed sensor.
Page 181 ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures Figure 12-11 Test 13: Speed Sensor Green Wire 6.1. Raise one rear wheel off ground. Slowly turn the rear wheel to rotate the motor armature. As the armature rotates, the voltage reading should alternate from zero to approximately 4.85 volts. The voltage reading will fluctuate from zero to 4.85 volts and back to zero four times for each revolution of the motor armature.
Page 182 Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING NOTE: Voltage can vary depending on controller speed setting as well as which zone a Guardian equipped vehicle is located. Example: Speed setting 1 may only read 30 volts. 4.1. If there is no voltage reading or if there is no increase in voltage as the pedal is pressed, check the MCOR. See MCOR Voltage on page 12-24.
Page 183 ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures 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 on page 12-11).
Page 184 Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-3. 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 185 ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures Pin 8 See General Warnings on page 1-2. Pin 8 in the 24-pin connector provides a connection point for the MCOR limit switch to the speed controller. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-3.
Page 186 Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING – Run/Tow switch for proper operation. See Run/Tow Switch on page 12-15. – Key switch and MCOR limit switch for proper operation. See Key Switch and MCOR Limit Switch Circuit on page 12-20. – Ensure that the pedal group is adjusted correctly. See Accelerator and Brake Pedal Group Section. Pin 19 See General Warnings on page 1-2.
Page 187 ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures Detail A: Front of 24-Pin Connector Figure 12-15 Test: Pin 19 (Orange/White Wire) Pins 10 and 11 See General Warnings on page 1-2. Pins 10 and 11 in the 24-pin connector provide a connection point for the Forward/Reverse rocker switch to the speed controller.
Page 188 Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING Place the Forward/Reverse switch in the FORWARD position. The multimeter should indicate full battery voltage (approximately 48 volts). Insert the red (+) probe of the multimeter into pin 11 (blue wire) of the 24-pin connector. Leave the black (–) probe (alligator clip) connected to the B–...
Page 189 ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures With a multimeter set for 200 volts DC, insert the red (+) probe of the multimeter into pin 1 (tan wire) of the 24-pin connector. See following CAUTION. With an alligator clip, connect the black (–) probe to the B– terminal of the speed controller (Figure 12-17, Page 12-37).
Page 190 Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING Set a multimeter to 200 volts DC. Use an alligator clip to connect the red (+) probe to the positive terminal on battery no. 1. With an insulation-piercing probe, connect the black (–) probe to the blue/white wire attached to pin 17 of the 24-pin connector.
Page 191 ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures TEST PROCEDURE 16 – Reverse Buzzer See General Warnings on page 1-2. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-3. Remove the instrument panel. See Instrument Panel Removal, Section 4, Page 4-9. Place the Run/Tow switch in the TOW position and connect the battery cables, positive (+) cable first.
Page 192 Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING TEST PROCEDURE 18 – Charge Indicator Light See General Warnings on page 1-2. With batteries connected, Run/Tow switch in the RUN position and the key switch in the OFF position, connect charger DC cord to vehicle. In a few seconds, the light will flash three times and the reverse buzzer simultaneously will sound three times to indicate charging has begun.
Page 193 ELECTRICAL SYSTEM TROUBLESHOOTING Test Procedures TEST PROCEDURE 19 – 4-Pin Connector (for Connected Car Device) See General Warnings on page 1-2. NOTE: This is a voltage and continuity test. Pin 1 – Yellow/Black Pin 4 – White/Black Pin 2 – Red/White Pin 3 –...
Page 194 Test Procedures ELECTRICAL SYSTEM TROUBLESHOOTING TEST PROCEDURE 20 – Emergency Stop Switch See General Warnings on page 1-2. WARNING • Motor braking and Walk Away braking functions are disabled when the emergency stop is activated. NOTE: This is a voltage test. If no voltage is coming to the Emergency Stop Switch, inspect the 4-gauge black wires and their connections.
Page 195: Section 13 - Electrical Components
SECTION 13 — ELECTRICAL COMPONENTS DANGER Electrical Components • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. KEY SWITCH See General Warnings on page 1-2. TESTING THE KEY SWITCH See Test Procedure 7 – Key Switch and MCOR Limit Switch Circuit on page 12-20. KEY SWITCH REMOVAL Disconnect the batteries and discharge the controller.
Page 196: Forward/Reverse Rocker Switch
Forward/Reverse Rocker Switch ELECTRICAL COMPONENTS Figure 13-1 Key Switch FORWARD/REVERSE ROCKER SWITCH See General Warnings on page 1-2. TESTING THE FORWARD/REVERSE ROCKER SWITCH See Test Procedure 8 – Forward/Reverse Rocker Switch on page 12-21. FORWARD/REVERSE ROCKER SWITCH REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-3.
Page 197: Run/Tow Switch
ELECTRICAL COMPONENTS Run/Tow Switch WARNING • Make sure that the vehicle operates in the forward direction when the Forward/Reverse switch is in the FORWARD position. • Make sure that the vehicle operates in the reverse direction when the Forward/Reverse switch is in the REVERSE position.
Page 198: Circuit Breaker
Circuit Breaker ELECTRICAL COMPONENTS CIRCUIT BREAKER See General Warnings on page 1-2. TESTING THE CIRCUIT BREAKER See Test Procedure 5 – Circuit Breaker on page 12-17 CIRCUIT BREAKER REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-3.
Page 199: Motor Controller Output Regulator (Mcor)
ELECTRICAL COMPONENTS Motor Controller Output Regulator (MCOR) MOTOR CONTROLLER OUTPUT REGULATOR (MCOR) See General Warnings on page 1-2. TESTING THE MCOR See Test Procedure 12 – MCOR Voltage on page 12-24 and Test Procedure 7 – Key Switch and MCOR Limit Switch Circuit on page 12-20.
Page 200: Reverse Buzzer
Reverse Buzzer ELECTRICAL COMPONENTS NOTE: Rotate the drive bar (5) back and forth if necessary to align the D-shaped end with the MCOR. Secure the MCOR (2) to the plastic housing (4) with two torx screws (3). Tighten screws to 12 in·lb (1.4 N·m). Connect the two-pin and three-pin connectors (1) from the wire harness to the MCOR (2).
Page 201: Solenoid
ELECTRICAL COMPONENTS Solenoid SOLENOID See General Warnings on page 1-2. The solenoid is located on the passenger side of the electrical component mounting plate. TESTING THE SOLENOID See Test Procedure 9 – Solenoid Activating Coil on page 12-22 and Test Procedure 10 – Solenoid Contacts on page 12-23.
Page 202: Speed Controller
Speed Controller ELECTRICAL COMPONENTS SPEED CONTROLLER See General Warnings on page 1-2. TESTING THE SPEED CONTROLLER See Test Procedure 14 – A1 and A2 Motor Voltage on page 12-29. SPEED CONTROLLER REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-3.
Page 203 ELECTRICAL COMPONENTS Speed Controller 2998 Figure 13-5 Speed Controller 2019 Transporter Maintenance and Service Manual Page 13-9...
Page 204: Charge Indicator Light
Charge Indicator Light ELECTRICAL COMPONENTS CHARGE INDICATOR LIGHT See General Warnings on page 1-2. TESTING THE CHARGE INDICATOR LIGHT See Test Procedure 18 – Charge Indicator Light on page 12-40. CHARGE INDICATOR LIGHT REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-3.
Page 205: Emergency Stop Switch Installation
ELECTRICAL COMPONENTS Emergency Stop Switch Figure 13-6 Emergency Stop Switch Components EMERGENCY STOP SWITCH INSTALLATION Installation is reverse of removal. Make sure to install the protective boot (3) over the switch (7) before installation. Tighten screws (2) to 35 in·lb (4 N·m). Tighten terminal screws (5) to 75 in·lb (8.5 N·m).
Page 206: Headlights
Headlights ELECTRICAL COMPONENTS HEADLIGHTS HEADLIGHT BEZEL REMOVAL Disconnect the batteries and discharge the controller. Remove the cowl. Remove the front fender. Disconnect the headlight and turn signal electrical connectors. Remove the bolts (1) (Figure 13-7, Page 13-12). Figure 13-7 Headlight Bezel Remove the headlight bezel (2).
Page 207: Halogen Headlight Bulb Removal
ELECTRICAL COMPONENTS Headlights HALOGEN HEADLIGHT BULB REMOVAL CAUTION • Do not touch the glass part of the headlight bulb. Oil from fingertips can decrease the life of the headlight bulb. Disconnect the batteries and discharge the controller. Remove the cowl. Lift the tabs on the connector harness to release the electrical connector from the headlight bulb (1) (Figure 13-8, Page 13-13).
Page 208: Halogen Headlight Lens Removal
Headlights ELECTRICAL COMPONENTS HALOGEN HEADLIGHT LENS REMOVAL CAUTION • Do not touch the glass part of the headlight bulb. Oil from fingertips can decrease the life of the headlight bulb. Disconnect the batteries and discharge the controller. Remove the cowl. Lift the tabs on the connector harness to release the electrical connector from the headlight bulb (1) (Figure 13-9, Page 13-14).
Page 209: Led Headlight Removal
ELECTRICAL COMPONENTS Lockout Relay LED HEADLIGHT REMOVAL Disconnect the batteries and discharge the controller. Remove the cowl. Lift the tabs on the connector harness to release the electrical connector from the LED headlight (1) (Figure 13-10, Page 13-15). 2993E Figure 13-10 LED Headlight Remove the screws (2).
Page 210: Lockout Relay Removal
Lockout Relay ELECTRICAL COMPONENTS LOCKOUT RELAY REMOVAL Disable the vehicle. Disconnect the batteries and discharge the controller. Remove the speed controller cover. Disconnect the wires from the lockout relay (1) (Figure 13-11). Remove the screws (2) and the lockout relay. LOCKOUT RELAY INSTALLATION Install the lockout relay (1) and screws (2) (Figure 13-11).
Page 211: Walk Away Relay
ELECTRICAL COMPONENTS Walk Away Relay WALK AWAY RELAY Figure 13-13 WALK AWAY RELAY REMOVAL Disable the vehicle. Disconnect the batteries and discharge the controller. Remove the speed controller cover. Disconnect the wires from the walk away relay (1) (Figure 13-13). Remove the screws (2) and the walk away relay.
Page 212 Walk Away Relay ELECTRICAL COMPONENTS Install the speed controller cover. Connect the batteries. Page 13-18 2019 Transporter Maintenance and Service Manual...
Page 213: Section 14 - Batteries
SECTION 14 — BATTERIES DANGER Batteries • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area.
Page 214: Battery Testing Basics - 6 Volt
Battery Testing Basics – 6 Volt BATTERIES BATTERY TESTING BASICS – 6 VOLT See General Warnings on page 1-2. OBSERVATION Inspect the battery compartment for the following items: • Rusted, corroded, or broken battery posts • Rusted, corroded, loose or broken wires •...
Page 215: Battery Testing - 6 Volt
Regrouping is now Club Car’s standard battery replacement method. Regrouping is the practice of placing batteries of similar condition together in one vehicle. For example, if there was an issue with the batteries in two cars and the battery test indicated three failed batteries in each car, after removing the failed batteries, there will be six good batteries remaining.
Page 216 Battery Regrouping BATTERIES 3104 Figure 14-2 Battery Regrouping Process Flow Page 14-4 2019 Transporter Maintenance and Service Manual...
Page 217: Battery Replacement
BATTERIES Battery Replacement BATTERY REPLACEMENT See General Warnings on page 1-2. WARNING • Wear steel-toe shoes when replacing batteries. • 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 218: Battery Care
See General Warnings on page 1-2. WATER QUALITY Water purity is the most important factor in the performance and life span of the vehicle batteries. Club Car is, therefore, placing increased importance on battery water quality. Outlined below are four battery watering procedures, grouped into two categories: Preferred and Alternate methods.
Page 219: Deionizer
Replace filter immediately if the red light comes ON indicating service is required. Replacement filters are available from Club Car Service Parts. • Inspect the condition of all tubing, connections, and couplers. Make sure that all parts are in good working condition, secure, leak free, and properly connected.
Page 220: Battery Care - Vehicles Equipped With The Single-Point Watering System (Spws)
Battery Care BATTERIES Single point watering systems will require seasonal maintenance if vehicles are taken out of service or put into storage for a period of 6 weeks or longer. To prepare the SPWS, ensure the feed tube and coupler are on top of battery. Then, use the following steps to bring vehicle back into service: After the batteries have been fully charged/equalized, connect the system to its water supply for 3 to 5 seconds, then disconnect regardless of whether or not the batteries are completely full.
Page 221: Battery Care - Vehicles Without The Single-Point Watering System (Spws)
• Do not overfill the batteries. NOTE: A battery watering gun or bottle is available from your authorized Club Car dealer. 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 222: Self-Discharge
Battery Care BATTERIES 1. Level Indicator 2. Cap 3. Plates Maintain electrolyte level from at least 1/2 inch (13 mm) above plates to 1/4 inch (6 mm) below level indicator. Figure 14-3 Electric Battery Electrolyte Level SELF-DISCHARGE Contaminants on dirty batteries can provide a path for a small current draw that can slowly discharge batteries, thus wasting valuable energy.
Page 223: Vibration Damage
A deionizer for vehicles with SPWS, Club Car Part Number 105166801 is available from Service Parts (DC powered water quality indicator light). Replacement cartridge: 104005901. Bottled distilled water, with hand pump, Club Car Part Number 104006101, is recommended for private consumer applications.
Page 224 Single Point Watering System (SPWS) BATTERIES • Do not use a longer garden hose than provided with the System (20 feet or 6 meters), as a decrease in water pressure can overfill the batteries and damage the refill system. Before screwing the hose-end assembly (3) onto the opposite end of the water hose, check the screen filter (4) inside the end of the assembly to make sure it is clean (Figure 14-4).
Page 225: Battery Storage
BATTERIES Battery Storage 2829 2830 Figure 14-6 Dust Cap Figure 14-7 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 226: Deep-Discharge
Deep-Discharge BATTERIES DEEP-DISCHARGE Never discharge batteries to the point the vehicle will no longer operate. This will considerably shorten the cycle life of the batteries, and may permanently damage the batteries. It is possible the batteries will not accept a charge if they are completely discharged.
Page 227: Section 15 - Battery Charger
If a charger cannot be properly identified, contact your local authorized Club Car dealer or distributor. The High Frequency Battery Charger functions as an integral part of the vehicles' electrical system and will not work with other electric vehicles.
Page 228: How To Identify Charge Algorithm Number
General Information BATTERY CHARGER HOW TO IDENTIFY CHARGE ALGORITHM NUMBER The algorithm numbers offered can be found in See Battery Charger Algorithms on page 15-2. The charger can display its algorithm number by initiating Algorithm Display Mode. To enter Algorithm Display Mode, do the following: Disconnect the AC cord from the power outlet.
Page 229: How To Change The Algorithm
BATTERY CHARGER General Information HOW TO CHANGE THE ALGORITHM Set the Run/Tow switch to TOW. If equipped, disconnect the DC/DC converter connector. Disconnect the AC cord. Disconnect the main positive (+) battery wire. Wait for 1 to 1.5 minutes. Connect the AC cord. While the battery charger lights flash, touch the main positive (+) battery wire to the battery post.
Page 230: Onboard Charger Operation
– Do not attempt to charge frozen batteries or batteries with bulged cases. Discard the battery in accordance with all environmental laws or return to an authorized Club Car dealer. Frozen batteries can explode.
Page 231 BATTERY CHARGER Onboard Charger Operation WARNING – Do not use an adapter to plug the charger with a three-prong plug into a two-prong outlet. Improper connection of the equipment-grounding conductor can result in a fire or an electrical shock. – Use only an appropriately sized AC power cord. See AC Power Connection on page 15-8. –...
Page 232: Charger Displays
Onboard Charger Operation BATTERY CHARGER CHARGER DISPLAYS 10-LED display on charger: 2379 Figure 15-4 10–LED Display on Charger Icon Indication (following LED Color STATUS EXPLANATION “Power-On Self Test”) Solid: Displays approximate scale of current output during bulk phase. Flashing: High internal charger temperature. Output reduced. Also displays algorithm Ammeter (Amber) #1 through # 6 for 11 seconds if no battery is connected.
Page 233 BATTERY CHARGER Onboard Charger Operation Solid: Charging is complete. Charger in Maintenance Mode. 100% Charge (Green) Flashing: Absorption phase complete. In Finish phase Solid: AC Power good AC on (Amber) Low AC Voltage. Check Voltage and power cord length (refer to guidelines) Flashing: See AC Power Connection on page 15-8.
Page 234: Ac Power Connection
Vehicles should be restricted to 40 to 50 amp hours of discharge between charges until the batteries have been properly seasoned (20 to 50 charge cycles). For maximum battery life, Club Car recommends that electric vehicles always be recharged after 40 to 50 amp hours of discharge or each night in order to avoid deep discharging the batteries.
Page 235: Maintenance
Any charger 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 WARNING •...
Page 236: Troubleshooting
Troubleshooting BATTERY CHARGER TROUBLESHOOTING See General Warnings on page 1-2. DANGER • Do not touch any wire or component in the battery charger while AC power is present. Failure to heed this warning will result in an electric shock. WARNING •...
Page 237: Test Procedures
BATTERY CHARGER Test Procedures TEST PROCEDURES See General Warnings, Section 1, Page 1-2. Index of Test Procedures 1 – Battery Voltage Using Multimeter 2 – Battery Condition Using Charger – All Batteries 3 – On-Charge Battery Voltage Using Charger And Multimeter 4 –...
Page 238: Charger Repairs
Charger Repairs BATTERY CHARGER TEST PROCEDURE 4 – AC Power and Continuity Test of AC Circuit Disconnect AC cord from the wall outlet and DC plug from the vehicle receptacle. Check the AC line fuse or circuit breaker in the storage facility. With a multimeter set to 500 volts AC, check incoming AC voltage.
Page 239: Onboard Charger Installation
BATTERY CHARGER Onboard Charger Removal And Installation Remove charger from vehicle. ONBOARD CHARGER INSTALLATION Install charger onto vehicle. Install the four lock nuts (5) securing charger to charger mounting plate. Tighten to 40 in·lb (5.4 N·m). Connect the AC and DC connector. Connect 8-pin grey connector.
Page 240 Onboard Charger Removal And Installation BATTERY CHARGER Pagination Page Page 15-14 2019 Transporter Maintenance and Service Manual...
Page 241: Section 16 - Motor
The IQ Plus vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. This 3.7 horsepower motor is designed for use on IQ Plus 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 242 External Motor Testing MOTOR TEST PROCEDURE 2 – Armature Circuit Open See General Warnings on page 1-2. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-3. 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 243: Motor Removal
MOTOR Motor Removal MOTOR REMOVAL See General Warnings on page 1-2. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-3. Disconnect wires from the terminals on the motor using two wrenches to prevent posts from turning. Label the wires to ensure proper reconnection.
Page 244 Motor Removal MOTOR Figure 16-3 Lower Axle Remove the four bolts that mount the motor to the transaxle (Figure 16-21, Page 16-16). See following CAUTION. CAUTION • Do not position fingers under motor when sliding motor off of the input shaft in step 9. Fingers may get pinched when motor disengages.
Page 245: Motor Disassembly
MOTOR Motor Disassembly MOTOR DISASSEMBLY Release the clasp and remove the headband assembly (21) from the motor. Visually inspect brushes and springs. (Figure 16-13, Page 16-10). Before continuing disassembly, place match marks on the motor end cap (20) and motor frame (14). Remove speed sensor (10) and magnet (12).
Page 246 Motor Disassembly MOTOR 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 247: Motor Component Testing And Inspection
MOTOR Motor Component Testing and Inspection MOTOR COMPONENT TESTING AND INSPECTION See General Warnings on page 1-2. ARMATURE INSPECTION AND TESTING Remove the motor from the vehicle. See Motor Removal, Section 16, Page 16-3. Remove the end cap and armature by performing steps 1 through 6 of Motor Disassembly on page 16-5. Visual Inspection •...
Page 248: Motor Frame And Field Windings Inspection
Motor Component Testing and Inspection MOTOR Figure 16-10 Armature Test MOTOR FRAME AND FIELD WINDINGS INSPECTION Remove the motor from the vehicle. See Motor Removal, Section 16, Page 16-3. Remove the end cap and armature by performing steps 1 through 6 of Motor Disassembly on page 16-5. Burned or scorched insulation on the field windings indicates the motor has overheated due to overloads or grounded or shorted coil windings.
Page 249 MOTOR Motor Component Testing and Inspection Install the brushes in the same rigging 180° apart from each other. Brush Inspection Remove the motor from the vehicle. See Motor Removal, Section 16, Page 16-3. Release the clasp and remove the headband from the motor. Inspect the brushes (16) for damage or excessive wear (Figure 16-13, Page 16-10).
Page 250 Motor Component Testing and Inspection MOTOR Figure 16-13 Motor Page 16-10 2019 Transporter Maintenance and Service Manual...
Page 251: Reconditioning The Motor
MOTOR Reconditioning the Motor RECONDITIONING THE MOTOR See General Warnings on page 1-2. 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 252 Motor Assembly MOTOR Figure 16-14 Retracted Brushes Figure 16-15 Armature Installation With the brushes retracted, use an arbor press to press the armature shaft into the end cap bearing (Figure 16-15, Page 16-12). See following CAUTION. CAUTION • Make sure the brushes are held back. Do not allow the brushes to support the weight of the commutator.
Page 253: Motor Installation
MOTOR Motor Installation A. End View B. Side View 3066 Figure 16-16 Speed Sensor Clamp MOTOR INSTALLATION See General Warnings on page 1-2. Clean the transaxle input shaft. 1.1. Spray the input shaft thoroughly with CRC ® Brakleen™ or equivalent brake cleaner degreaser. 1.2.
Page 254 Motor Installation MOTOR inch inch 1/8 INCH 3/8 INCH (9.5 MM) (3.1 MM) Figure 16-17 Grease on Putty Knife Figure 16-18 Application of grease to Input Shaft Grooves 2.6. Check the chamfer (1) and end (2) of the input shaft to ensure these areas are completely clean of grease as shown (Figure 16-19, Page 16-15).
Page 255 MOTOR Motor Installation 1/16 INCH (1.6 MM) Figure 16-19 Clean Chamfer and Input Shaft End Figure 16-20 Gap at Motor and Transaxle 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 256 Motor Installation MOTOR Viewed From Driver Side Figure 16-21 Motor Tightening Sequence Page 16-16 2019 Transporter Maintenance and Service Manual...
Page 257: Section 17 - Transaxle
SECTION 17 — TRANSAXLE DANGER Transaxle • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. LUBRICATION See General Warnings on page 1-2. 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 258 Axle Bearing and Shaft TRANSAXLE Inspect the axle shaft assembly to be sure the bearing and collar have not slipped and are still seated against the shoulder on the axle shaft. Inspect bearing (5) (Figure 17-5, Page 17-3). If the bearing in a Type G transaxle is worn or damaged, the entire axle shaft assembly (1 or 2) must be replaced.
Page 259 TRANSAXLE Axle Bearing and Shaft Figure 17-5 Transaxle – Type G 2019 Transporter Maintenance and Service Manual Page 17-3...
Page 260: Axle Bearing
Axle Bearing and Shaft TRANSAXLE 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 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 (Figure 17-3, Page 17-2).
Page 261: Transaxle
TRANSAXLE Transaxle TRANSAXLE See General Warnings on page 1-2. TRANSAXLE REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-3. Place chocks at the front wheels and slightly loosen lug nuts on both rear wheels. Place a floor jack under the transaxle and raise the rear of the vehicle.
Page 262 Transaxle TRANSAXLE 2629 2631 Figure 17-8 Disconnect Shocks Figure 17-9 Detach Spring From Shackles Disconnect the shock absorbers from their lower mounts (Figure 17-8, Page 17-6). Disconnect the four motor wires. Use two wrenches to prevent the post from turning. With a floor jack supporting the transaxle, remove lower spring shackle nuts and bolts.
Page 263 TRANSAXLE Transaxle CAUTION 1. Motor Mounting Bolts 2. Input Pinion Gear 3. Intermediate Gear Assembly 4. Differential Gear Case 2639 Figure 17-11 Motor Mounting Bolts and Gear Assembly Figure 17-10 Detach Axle From Leaf Springs 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 264: Transaxle Disassembly, Inspection, And Assembly
Transaxle Disassembly, Inspection, and Assembly TRANSAXLE TRANSAXLE DISASSEMBLY, INSPECTION, AND ASSEMBLY See General Warnings on page 1-2. TRANSAXLE DISASSEMBLY AND INSPECTION To detach axle tubes (14 and 35) from the transaxle housing, remove the bolts (8) (Figure 17-5, Page 17-3). Remove 11 bolts (24) that hold housing together.
Page 265 TRANSAXLE 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 17-5, Page 17-3). 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 17-14, Page 17-9).
Page 266: Transaxle Assembly
Transaxle Disassembly, Inspection, and Assembly TRANSAXLE NOTE: Damaged or worn gears should be replaced as sets. 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 17-5, Page 17-3).
Page 267: Transaxle Installation
TRANSAXLE 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. Make sure the drain plug (22) is installed in the transaxle and tightened to 23 ft·lb (31 N·m).
Page 268 Transaxle Installation TRANSAXLE WARNING • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. Page 17-12 2019 Transporter Maintenance and Service Manual...
Page 269: Section 18 - Wiring Diagrams
SECTION 18 — WIRING DIAGRAMS GENERAL INFORMATION Wiring Diagrams Wire Description EXAMPLE: 18_GRN_RED • 18 = 18 gauge wire • GRN_RED = Green wire with red stripe Wire Colors NOTE: The following colors will represented as a black wire in the wiring diagrams: •...
Page 270: General Information
General Information WIRING DIAGRAMS GRN_WHT Green with White Stripe ORG_BLK Orange with Black Stripe ORG_WHT Orange with White Stripe PUR_WHT Purple with White Stripe RED_GRN Red with Green Stripe RED_WHT Red with White Stripe RED_YEL Red with Yellow Stripe WHT_BLK White with Black Stripe Page 18-2 2019 Transporter Maintenance and Service Manual...
Page 271 Wiring Diagrams Electric: Main Harness ELECTRIC: MAIN HARNESS...
Page 272 (Page intentionally left blank.)
Page 273 Wiring Diagrams Electric: Instrument Panel Harness ELECTRIC: INSTRUMENT PANEL HARNESS...
Page 274 (Page intentionally left blank.)
Page 275 Wiring Diagrams Electric: Accessories Harness ELECTRIC: ACCESSORIES HARNESS...
Page 276 (Page intentionally left blank.)
Page 277: Index
Index Index emergency brake system ........6-19 Index adjustment............6-20 AC power and circuit installation ............6-20 testing (QuiQ charger) ........15-12 removal ............6-19 accelerator pedal pedal (electric) height adjustment (electric)........ 5-8 height adjustment..........5-10 installation ............5-2 installation ............5-7 removal ............
Page 278 INDEX system info menu ..........11-5 removal ............. 4-21 troubleshooting ..........11-27 electric motor vehicle date of manufacture .......11-10 see motor ............16-1 vehicle decal .............11-10 electrical system ............ 12-1 vehicle s/n ............11-10 testing circuits ...........12-11 walkaway deterrent ..........11-8 electrolyte tray CDT General Info ..........
Page 279 INDEX removal ............... 4-9 see regenerative braking ........12-2 motor controller output regulator (MCOR) testing ........... 12-20, 12-24 motor controller output regulator 3 (MCOR) installation ............13-5 key switch removal ............. 13-5 installation ............13-1 removal ............. 13-1 testing ............. 12-20 park brake adjustment (electric) ..........
Page 280 INDEX specifications, vehicle ..........2-1 4-pin connector ..........12-41 speed controller batteries/voltage check ........12-12 connector, 24-pin battery pack voltage (under load) ...... 12-14 see test procedures........12-30 charge indicator light ........12-40 installation ............13-8 charger interlock..........12-23 removal ............. 13-8 circuit breaker ..........
Page 281 INDEX see test procedures........12-41 walk away braking ..........12-1 walk away braking relay testing ............. 12-39 walk away relay ........... 13-17 installation ............13-17 removal ............13-17 WARNING definition of ............1-1 water level see batteries, electrolyte level ......14-10 wheel installation ............
Page 282 NOTES...
Page 283 NOTES...
Page 284 NOTES...

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