Page 1 2014 Precedent ® Golf Car Maintenance and Service Manual Electric Vehicle with PowerDrive™ Battery Charger Gasoline Vehicle with Kawasaki FE350 Engine Electric Vehicle with ERIC Charging System Manual Number 105062901 Edition Code 0713A00000...
Page 3 If it appears that a service question is not answered in this manual, please contact your nearest authorized Club Car dealer or distributor for assistance. You may also write to us at: Club Car, LLC, P.O. Box 204658; Augusta, GA 30917–4658 USA, Attention: Technical Services.
Page 5: Table Of Contents
CONTENTS SECTION 1 – SAFETY ............................1-1 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 Battery – Gasoline Vehicles .................... 1-3 Connecting the Battery – Gasoline Vehicles ....................1-4 Disconnecting the Batteries –...
Page 6 Kick Plate and Choke Button Removal ...................... 4-10 Kick Plate and Choke Button Installation ....................4-10 Seat Bottom ..............................4-11 Rear Body – Two-Passenger Vehicles......................4-12 Universal Accessory Mounting........................4-12 Seat Back and Structural Accessory Module (SAM) ................... 4-12 Rear Body Components (Two-Passenger)....................4-14 Rear Body –...
Page 7 Rack and Pinion Installation ........................7-5 Front Suspension ............................7-6 Lubrication ..............................7-6 Wheel Alignment ............................7-6 Front Suspension Components........................7-8 Tie Rod End Removal ..........................7-8 Tie Rod Installation ............................ 7-8 Leaf Spring Removal ..........................7-9 Leaf Spring Installation..........................7-9 Kingpin and Steering Spindle Removal .......................
Page 8 Menu Navigation ............................11-3 Program (IQDM-P only) ..........................11-4 Monitor ..............................11-4 Faults ..............................11-4 Functions ..............................11-4 Information...............................11-4 Programmer Setup ...........................11-4 Monitor Menu ...............................11-5 Speed ..............................11-5 Throttle ..............................11-5 Batt Aux Voltage ............................11-5 Temperature.............................11-5 Arm Current .............................11-6 Field Current ............................11-6 Armature PWM............................11-6 Field PWM ...............................11-6 Brake Volts In ............................11-6 Speed Pulses ............................11-6 Foot Input ..............................11-6...
Page 9 Program..............................11-19 Faults ..............................11-19 Information............................. 11-19 IQDM and IQDM-P Handset Troubleshooting ....................11-20 Test Procedures ............................11-21 SECTION 12 – IQ DISPLAY MODULE PROGRAMMER (IQDM-P): EXCEL SYSTEM WITH POWERDRIVE CHARGER..............................12-1 Plugging the Handset into the Vehicle ......................12-1 Program Menu ............................
Page 10 Reverse Buzzer Removal......................... 14-8 Reverse Buzzer Installation ........................14-8 Electronics Module ............................14-9 Electronics Module Removal ........................14-9 Electronics Module Installation ........................14-10 Speed Controller ............................14-12 Testing the Solid State Speed Controller ....................14-12 Speed Controller Removal ........................14-12 Speed Controller Installation........................14-12 Solenoid..............................14-13 Testing the Solenoid ..........................14-13 Solenoid Removal ..........................14-13 Solenoid Installation..........................14-13...
Page 11 SECTION 16 – BATTERY CHARGER: POWERDRIVE..................16-1 SECTION 17 – MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE ..............17-1 General Information ............................. 17-1 External Motor Testing ..........................17-1 Motor ................................17-4 Motor Removal ............................17-4 Motor Disassembly ..........................17-5 Motor Component Testing and Inspection...................... 17-8 Armature Inspection and Testing.......................
Page 12 Key Switch ..............................20-14 Testing the Key Switch ..........................20-14 Key Switch Removal ..........................20-14 Key Switch Installation ..........................20-15 Solenoid..............................20-15 Testing the Solenoid ..........................20-15 Solenoid Removal ..........................20-15 Solenoid Installation..........................20-15 Fuse ................................20-16 Testing the Fuse .............................20-16 Fuse Removal ............................20-16 Fuse Installation .............................20-16 Limit Switches ............................20-16 Accelerator Pedal Limit Switch ........................20-16 Kill Limit Switch ............................20-17 Neutral Lockout Limit Switch ........................20-17...
Page 13 SECTION 21 – AS26 FE 350 ENGINE ......................21-1 General Information ............................. 21-1 Before Servicing ............................21-1 Engine Rotation............................21-1 Spark Plug .............................. 21-2 Cylinder Head ............................. 21-3 General Information ..........................21-3 Breather Valve (Reed Valve)........................21-3 Valve Clearance Check and Adjustment....................21-3 Crankcase..............................
Page 14 SECTION 23 – EXHAUST SYSTEM ......................... 23-1 Muffler ................................ 23-1 Muffler Removal ............................23-1 Muffler Installation............................ 23-1 SECTION 24 – UNITIZED TRANSAXLE (GASOLINE VEHICLE) ............... 24-1 General Information ............................. 24-1 Shifter Lever............................24-1 Neutral Lockout ............................24-1 Governor System............................. 24-2 Unitized Transaxle Service ........................
Page 15 Monitor Menu .............................. 26-5 Batt Voltage............................. 26-5 BDI Percent............................. 26-5 Speed ..............................26-6 Throttle ..............................26-6 Temperature............................26-6 Arm Current ............................26-6 Field Current ............................26-6 Armature PWM............................26-6 Field PWM .............................. 26-6 Speed Pulses ............................26-6 Foot Input ............................... 26-7 Key Input ..............................
Page 16 Param Block Version..........................26-20 MFG Date ..............................26-20 Programmer Setup .............................26-21 Program..............................26-21 Faults ..............................26-21 Information.............................26-21 IQDM and IQDM-P Handset Troubleshooting ....................26-22 Test Procedures ............................26-23 SECTION 27 – IQ DISPLAY MODULE PROGRAMMER (IQDM-P): EXCEL SYSTEM WITH ERIC CHARGING ..............................27-1 Plugging the Handset into the Vehicle ......................27-1 Program Menu ............................
Page 17 Electronics Module ............................29-9 Electronics Module Removal ........................29-9 Electronics Module Installation ........................29-10 Speed Controller ............................29-11 Testing the Solid State Speed Controller ....................29-11 Speed Controller Removal ........................29-11 Speed Controller Installation........................29-11 Solenoid..............................29-12 Testing the Solenoid ..........................29-12 Solenoid Removal ..........................29-13 Solenoid Installation..........................29-13 Charger Receptacle ............................29-13 Testing the Charger Receptacle.......................29-13...
Page 18 USB Service Port............................31-13 Incoming AC Service ..........................31-13 Terminal Block Cover ..........................31-14 Resetting Power – External Charger ......................31-14 Resetting Power – Onboard Charger .......................31-14 Charger Troubleshooting Indicators ......................31-15 Test Procedures ............................31-16 External Charger Repairs ..........................31-19 Terminal Block Cover Removal ........................31-19 Terminal Block Cover Installation ......................31-20 DC Cord and Strain Relief Removal ......................31-20 DC Cord and Strain Relief Installation ......................31-20 Handle Removal .............................31-21...
Page 19: Section 1 - Safety
SECTION 1 – SAFETY SAFETY DETAILS 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 20: 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 21: Disabling The Vehicle
SAFETY General Warnings WARNING • Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance, severe personal injury, or death. • Any modification or change to the vehicle that affects the electrical system, stability or handling of the vehicle, or increases maximum vehicle speed beyond factory specifications, could result in severe personal injury or death.
Page 22: Connecting The Battery - Gasoline Vehicles
General Warnings SAFETY Disconnect the battery cables, negative (–) cable first, as shown (Figure 1-2). Disconnect the spark plug wire(s) from the spark plug(s). CONNECTING THE BATTERY – GASOLINE VEHICLES Connect the battery cables, positive (+) cable first. Tighten battery terminals to 80 in·lb (9 N·m). Coat terminals with Battery Terminal Protector Spray (CC P/N 1014305) to minimize corrosion.
Page 23: Recycling Lead-Acid Batteries
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 25: Section 2 - Vehicle Specifications
SECTION 2 – VEHICLE SPECIFICATIONS VEHICLE SPECIFICATIONS NOTE: Engine horsepower specifications are provided by the engine manufacturer. Actual horsepower in use may differ and is dependent on environmental conditions as well as the maintenance condition of the engine. TWO- TWO- FOUR- FOUR- PASSENGER...
Page 26 Vehicle Specifications VEHICLE SPECIFICATIONS TWO- TWO- FOUR- FOUR- PASSENGER PASSENGER PASSENGER PASSENGER SPECIFICATIONS ELECTRIC GASOLINE ELECTRIC GASOLINE VEHICLE VEHICLE VEHICLE VEHICLE Brakes: Dual rear wheel self-adjusting brakes with cast iron drums and single brake pedal with ● ● ● ● automatic-release park brake BODY/CHASSIS Frame/Chassis: Aluminum and composite...
Page 27: Charger Specifications
VEHICLE SPECIFICATIONS Charger Specifications TWO- TWO- FOUR- FOUR- PASSENGER PASSENGER PASSENGER PASSENGER SPECIFICATIONS ELECTRIC GASOLINE ELECTRIC GASOLINE VEHICLE VEHICLE VEHICLE VEHICLE NOISE AND VIBRATION Drive-by noise level to operator 68.5 dBA 70.9 dBA 68.5 dBA 70.9 dBA Test method: EN 12053:2001 Uncertainty: 2 dBA Uncertainty: 2 dBA Uncertainty: 2 dBA...
Page 29: 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 30: Safety Committee
• Where golf cars should be driven. • Ensuring that proper warnings of driving hazards are displayed and visible. See below for list of signs available from Club Car Service Parts Department. • Who should and who should not drive golf cars.
Page 31: Storage - Electric Vehicle With Eric Battery Charger
GENERAL INFORMATION Storage – Electric Vehicle with ERIC Battery Charger STORAGE – ELECTRIC VEHICLE WITH ERIC BATTERY CHARGER See General Warnings on page 1-2. WARNING • Turn the key switch to the OFF position, remove the key, and leave the Forward/Reverse switch in the NEUTRAL position during storage.
Page 32: Returning The Stored Electric Vehicle To Service
Storage – Electric Vehicle with ERIC Battery Charger GENERAL INFORMATION Perform all semiannual periodic lubrication. See Periodic Lubrication Schedules on page 10-7. Thoroughly clean front body, rear body, seats, battery compartment, and underside of vehicle. 10. Do not engage the park brake. Chock the wheels to prevent the vehicle from rolling. NOTE: It is recommended that the vehicles be plugged in and the electrolyte level maintained throughout the storage period.
Page 33: Storage - Electric Vehicle With Powerdrive Battery Charger
GENERAL INFORMATION Storage – Electric Vehicle with PowerDrive Battery Charger STORAGE – ELECTRIC VEHICLE WITH POWERDRIVE BATTERY CHARGER See General Warnings on page 1-2. WARNING • Turn the key switch to the OFF position, remove the key, and leave the Forward/Reverse switch in the NEUTRAL position during storage.
Page 34: Returning The Stored Electric Vehicle To Service
Storage – Electric Vehicle with PowerDrive Battery Charger GENERAL INFORMATION Perform all semiannual periodic lubrication. See Periodic Lubrication Schedules on page 10-7. Thoroughly clean front body, rear body, seats, battery compartment, and underside of vehicle. 10. Do not engage the park brake. Chock the wheels to prevent the vehicle from rolling. NOTE: It is recommended that the vehicles be plugged in and the electrolyte level maintained throughout the storage period.
Page 35: Storage - Gasoline Vehicle
GENERAL INFORMATION Storage – Gasoline Vehicle STORAGE – GASOLINE VEHICLE See General Warnings on page 1-2. DANGER • Do not attempt to drain fuel when the engine is hot or while it is running. • Be sure to clean up any spilled gasoline before operating the vehicle. •...
Page 36: Returning The Stored Gasoline Vehicle To Service
Storage – Gasoline Vehicle GENERAL INFORMATION Adjust tires to recommended tire pressure. See Vehicle Specifications on page 2-1. Perform semiannual periodic lubrication. See Periodic Lubrication Schedules on page 10-7. Thoroughly clean front body, rear body, seats, engine compartment, and underside of vehicle. Do not engage the park brake.
Page 37: Fueling Instructions - Gasoline Vehicles
GENERAL INFORMATION Fueling Instructions – Gasoline Vehicles FUELING INSTRUCTIONS – GASOLINE VEHICLES See General Warnings on page 1-2. DANGER • Turn the key switch to the OFF position before fueling. • Do not pour fuel into the fuel tank when the engine is hot or while it is running. •...
Page 39: Section 4 - Body And Trim
A garden hose at normal residential water pressure is adequate. Club Car does not recommend any type of pressure washing or steam cleaning. Such a process (especially if the vehicle has a Surlyn ®...
Page 40: Front And Rear Body Repair
Front and Rear Body Repair BODY AND TRIM Difficult Stains: Dampen a soft, white cloth with a solution of 10% household bleach (sodium hypochlorite) and 90% water. Rub gently to remove stain, then rinse with a water dampened cloth to remove bleach concentration. More Difficult Stains: Perform previous procedure using full-strength bleach, or allow bleach to puddle on affected area for approximately 30 minutes.
Page 41: Minor Scratches And Surface Blemishes
BODY AND TRIM Front Body MINOR SCRATCHES AND SURFACE BLEMISHES For minor scratches or blemishes in the Surlyn ® body that do not penetrate the finish: Thoroughly clean the affected area using a strong, non-abrasive detergent and hot water, then clean with Ultra-Kleen ®...
Page 42 Front Body BODY AND TRIM Figure 4-1 Front Body Page 4-4 2014 Precedent ® Golf Car Maintenance and Service Manual...
Page 43: Front Bumper
BODY AND TRIM Front Bumper FRONT BUMPER The underbody bracket (1) connects the front suspension to the front underbody (Figure 4-2, Page 4-5). Each bracket is secured in place by two taptite screws (2) tightened to 13 ft·lb (17.6 N·m). The front bumper (3) is attached to the vehicle frame rails by nuts (5) and bolts (4).
Page 44: Headlight Adjustment
Headlight Adjustment BODY AND TRIM HEADLIGHT ADJUSTMENT Headlights are available as an accessory on this vehicle. To raise or lower the headlight beam, washers can be added to the mounting hardware between the headlight and the bumper assembly. See General Warnings on page 1-2. AIMING THE HEADLIGHT BEAM Park the vehicle on a level surface 5 feet away from, and facing a vertical surface such as a garage door or wall.
Page 45: Instrument Panel
BODY AND TRIM Instrument Panel INSTRUMENT PANEL See General Warnings on page 1-2. INSTRUMENT PANEL REMOVAL Remove two screws (1) at sides and one screw (2) on top of instrument panel (3) (Figure 4-4, Page 4-7). Tilt instrument panel up to release it from the dash assembly (4). Disconnect the electrical connector on the passenger side of the instrument panel (3) and remove the panel.
Page 46: Floor Mat And Retainers
Floor Mat and Retainers BODY AND TRIM FLOOR MAT AND RETAINERS See General Warnings on page 1-2. The floor mat retainers secure the floor mat to the vehicle and also provide a clean appearance to the side of the vehicle. Normally, if only the floor mat (3) needs to be removed, the screws (2) must be removed to allow the floor mat to be slid from beneath the retainers (1) (Figure 4-5, Page 4-8).
Page 47: Kick Plate And Charger Receptacle Bezel
BODY AND TRIM Kick Plate and Charger Receptacle Bezel KICK PLATE AND CHARGER RECEPTACLE BEZEL See General Warnings on page 1-2. KICK PLATE AND CHARGER RECEPTACLE BEZEL REMOVAL If charger bezel (4) requires removal, use charger bezel tool (P/N 102562401) to remove bezel from the kick plate (Figure 4-6, Page 4-9).
Page 48: Kick Plate And Choke Button Bezel
Kick Plate and Choke Button Bezel BODY AND TRIM KICK PLATE AND CHOKE BUTTON BEZEL See General Warnings on page 1-2. KICK PLATE AND CHOKE BUTTON REMOVAL Access the inside of the fuel bucket and disconnect hair spring cotter pin (2) from choke rod (3). Remove rod from the choke (Figure 4-7, Page 4-11).
Page 49: Seat Bottom
BODY AND TRIM Seat Bottom Figure 4-7 Kick Plate and Choke Button SEAT BOTTOM The seat bottom (1) is secured to the vehicle with two hinges (2) (Figure 4-8, Page 4-11) that hook into slots in the body. When replacing the hinges (2), tighten screws (3) to 75 in·lb (8.5 N·m). When replacing hip restraints (4), tighten screws (5) to 65 in·lb (7.3 N·m).
Page 50: Rear Body - Two-Passenger Vehicles
Rear Body – Two-Passenger Vehicles BODY AND TRIM REAR BODY – TWO-PASSENGER VEHICLES See General Warnings on page 1-2. UNIVERSAL ACCESSORY MOUNTING NOTE: The Structural Accessory Module (SAM) uses clearance holes for accessories to attach to the canopy support located inside the SAM. The Structural Accessory Module (SAM) includes two mounting locations on both the driver side and the passenger side (Figure 4-9, Page 4-12).
Page 51 BODY AND TRIM Rear Body – Two-Passenger Vehicles Sweater Basket The sweater basket (11) is secured to the bag hoop assembly by three screws (12). Tabs on the upper edge of the basket align with holes in the bag hoop (6) for installation purposes. Tighten screws (12) to 31 in·lb (3.5 N·m) for molded-plastic sweater basket (Figure 4-10, Page 4-13).
Page 52: Rear Body Components (Two-Passenger)
Rear Body – Two-Passenger Vehicles BODY AND TRIM REAR BODY COMPONENTS (TWO-PASSENGER) Rear Beauty Panel Removal Remove SAM. See SAM Removal on page 4-12. Remove one screw (3) from each canopy support bracket (1 and 2) (Figure 4-11, Page 4-15). Remove canopy supports.
Page 53 BODY AND TRIM Rear Body – Two-Passenger Vehicles * Two-Passenger Vehicles Only 2656 Figure 4-11 Rear Body Components 2014 Precedent ® Golf Car Maintenance and Service Manual Page 4-15...
Page 54: Rear Body - Four-Passenger Vehicles
Rear Body – Four-Passenger Vehicles BODY AND TRIM REAR BODY – FOUR-PASSENGER VEHICLES See General Warnings on page 1-2. SEAT BACKS Seat Back Removal Remove screws (9 or 13) securing seat back (8 or 11) to seat support and remove the seat back (Figure 4-12, Page 4-16).
Page 55: Seat Support
BODY AND TRIM Rear Body – Four-Passenger Vehicles SEAT SUPPORT Seat Support Removal Remove screws (11 and 14) securing the rear hip restraints (6) and remove the hip restraints from the vehicle (Figure 4-13, Page 4-17). Remove the screws (5) and bolts (4) from the seat supports (3) and remove the seat supports from the vehicle. Seat Support Installation Install in the reverse order of removal.
Page 56: Foot Deck
Rear Body – Four-Passenger Vehicles BODY AND TRIM FOOT DECK Foot Deck Removal Remove screws (11 and 14) securing the rear hip restraints (6) and remove the hip restraints from the vehicle (Figure 4-13, Page 4-17). Remove the four bolts (2) securing the foot deck (1) to the vehicle frame (Figure 4-14, Page 4-18). Foot Deck Installation Install foot rest in reverse order of removal.
Page 57: Canopy - Two-Passenger
BODY AND TRIM Canopy – Two-Passenger Rear Beauty Panel Installation Install rear beauty panel (12) on vehicle. Make sure body clips (17) on the rear of the beauty panel engage the slots in the rear underbody (4) (Figure 4-11, Page 4-15). Secure beauty panel in place with four screws (13).
Page 58 Canopy – Two-Passenger BODY AND TRIM 2378 Figure 4-15 Precedent Two-Passenger Canopy Page 4-20 2014 Precedent ® Golf Car Maintenance and Service Manual...
Page 59: Two-Passenger Canopy Installation
BODY AND TRIM Canopy – Two-Passenger TWO-PASSENGER CANOPY INSTALLATION Install the front canopy supports. 1.1. Ensure the front supports are properly oriented to the correct side of the vehicle as shown (Figure 4-15, Page 4-20). The lower profile of each support follows the profile of the vehicle. If the supports are placed on the wrong side of the vehicle, they will not follow the vehicle’s profile.
Page 60: Canopy - Four-Passenger
Canopy – Four-Passenger BODY AND TRIM CANOPY – FOUR-PASSENGER See General Warnings on page 1-2. CAUTION • To prevent damage to the canopy, do not remove the canopy supports (1 and 6) from the vehicle without first removing the canopy (9) (Figure 4-16, Page 4-23). FOUR-PASSENGER CANOPY REMOVAL Remove the two nuts (12), two bolts (11), and spacers (10) from the canopy (9), and each front canopy support (1) (Figure 4-16, Page 4-23).
Page 61 BODY AND TRIM Canopy – Four-Passenger Figure 4-16 Precedent Four-Passenger Canopy 2014 Precedent ® Golf Car Maintenance and Service Manual Page 4-23...
Page 62: Canopy (Monsoon Version) - Four-Passenger
Canopy (Monsoon Version) – Four-Passenger BODY AND TRIM CANOPY (MONSOON VERSION) – FOUR-PASSENGER See General Warnings on page 1-2. CAUTION • To prevent damage to the canopy, do not remove the canopy supports (1, 2, 8 and 9) from the vehicle without first removing the canopy (13) (Figure 4-19, Page 4-27).
Page 63 BODY AND TRIM Canopy (Monsoon Version) – Four-Passenger K-00834 Figure 4-17 Secure Rear Drain Struts to Seat Supports Attach the front struts. 2.1. Ensure the front struts are properly oriented to the correct side of the vehicle as shown (Figure 4-18). The lower profile of each support follows the profile of the vehicle.
Page 64 Canopy (Monsoon Version) – Four-Passenger BODY AND TRIM K-00504 Figure 4-18 Properly Orient the Front Supports With the aid of an assistant, position the canopy (13) to the top of the front struts (8 and 9) and rear drain struts (1 and 2). Secure the front canopy brackets (under the canopy) (14) to the front struts (8 and 9) with four grey M6x1 x 45 hex head bolts (15), eight rubber faced conical washers (20) and four M6 flanged nylon lock nuts (17).
Page 65 BODY AND TRIM Canopy (Monsoon Version) – Four-Passenger K-00835 Figure 4-19 Secure Canopy 2014 Precedent ® Golf Car Maintenance and Service Manual Page 4-27...
Page 67: Section 5 - Accelerator And Brake Pedal Group
SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP DANGER • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. PEDAL GROUP – ELECTRIC VEHICLE See General Warnings on page 1-2. PEDAL GROUP REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4.
Page 68: Mcor3
Pedal Group – Electric Vehicle ACCELERATOR AND BRAKE PEDAL GROUP Lift pedal group from vehicle. 2518 Figure 5-2 Pedal Group – Electric Vehicle MCOR3 The pedal group for the Precedent electric vehicle includes a Motor Controller Output Regulator 3 (MCOR3) mounted on the side of the pedal group.
Page 69: Pedal Group Installation
ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group – Electric Vehicle • Test Procedure 8 – Key Switch and MCOR3 Limit Switch Circuit on page 13-20 • MCOR3 Removal on page 14-7 • MCOR3 Installation on page 14-7 PEDAL GROUP INSTALLATION Connect the wire harness (12) to the MCOR3 (13) (Figure 5-2, Page 5-2).
Page 70: Pedal Group - Gasoline Vehicle
Pedal Group – Gasoline Vehicle ACCELERATOR AND BRAKE PEDAL GROUP PEDAL GROUP – GASOLINE VEHICLE See General Warnings on page 1-2. PEDAL GROUP REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-3. Remove screws (1).
Page 71: Throttle Position Sensor
ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group – Gasoline Vehicle Figure 5-4 Pedal Group – Gasoline Vehicle THROTTLE POSITION SENSOR The pedal group for the Precedent vehicle includes a throttle position sensor mounted on the side of the accelerator pedal assembly. The throttle position sensor detects the position of the accelerator pedal and sends a voltage to the solenoid and forward/reverse limit switches.
Page 72: Pedal Group Installation
Debris Shields ACCELERATOR AND BRAKE PEDAL GROUP PEDAL GROUP INSTALLATION Connect the end of the accelerator cable to the pedal group (Figure 5-4, Page 5-5). See following CAUTION. CAUTION • Make sure the accelerator cable is properly seated to the pedal group. Connect the wire harness (12) to the throttle position sensor (Figure 5-4, Page 5-5).
Page 73: Brake Pedal Removal
ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal Removal Electric Vehicle: Install the MCOR3. See MCOR3 Installation on page 14-7. Install pedal group in vehicle. See Pedal Group Installation on page 5-3. See Pedal Group Installation on page 5-6. BRAKE PEDAL REMOVAL Remove pedal group from vehicle.
Page 74 Brake Pedal Installation ACCELERATOR AND BRAKE PEDAL GROUP 000487-002 Figure 5-5 Accelerator Pedal Assembly and Brake Pedal Assembly Page 5-8 2014 Precedent ® Golf Car Maintenance and Service Manual...
Page 75: Section 6 - Wheel Brake Assemblies
SECTION 6 – WHEEL BRAKE ASSEMBLIES DANGER • 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 76 Brake Shoe Removal WHEEL BRAKE ASSEMBLIES 1400-18100-10220 Figure 6-1 Loosen Turnbuckle Figure 6-2 Shoe Retainer Pins Remove brake drums and badly worn brake shoes. 7.1. On the back of each brake cluster assembly, locate the heads of two brake shoe retainer pins. It may be necessary to remove sealant material around the head of each pin.
Page 77 WHEEL BRAKE ASSEMBLIES Brake Shoe Removal 2731 Figure 6-4 Self-adjusting Wheel Brake Assembly Using needle nose pliers, turn the clip retainer pin (1) 90° to remove the shoe retainer clip (2) (Figure 6-5, Page 6-4). CAUTION • The brake shoes are under pressure and can release suddenly when brake shoe retainers are removed. 10.
Page 78 Brake Shoe Removal WHEEL BRAKE ASSEMBLIES 1400-18100-10222 1400-17700-10225 Figure 6-5 Remove Shoe Retainer Clip Figure 6-6 Remove Brake Shoes 1. Slide 2733 2732 Figure 6-7 Remove Adjuster Wheel Figure 6-8 Lubricate Slide Page 6-4 2014 Precedent ® Golf Car Maintenance and Service Manual...
Page 79: Brake Assembly Cleaning
WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning 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 of its mechanical components. Remove the rubber boot from backing plate and wipe with a clean damp cloth. Lubricate the slide (1) with dry moly lubricant (P/N 1012151) (Figure 6-8, Page 6-4).
Page 80 Brake Assembly Cleaning WHEEL BRAKE ASSEMBLIES 2735 2736 Figure 6-11 Apply Grease To Brake Adjuster Figure 6-12 Install Adjuster Wheel, Trailing Shoe Page 6-6 2014 Precedent ® Golf Car Maintenance and Service Manual...
Page 81: Brake Shoe Installation
WHEEL BRAKE ASSEMBLIES Brake Shoe Installation BRAKE SHOE INSTALLATION See General Warnings on page 1-2. See also Asbestos Dust Warning on page 6-1. Turn the adjusting wheel screw so that the shoe slot is vertical, then position the trailing shoe in the slots in the shoe mounting block and adjuster assembly (Figure 6-12, Page 6-6).
Page 82 Brake Shoe Installation WHEEL BRAKE ASSEMBLIES Figure 6-15 Install Leading Shoe Figure 6-16 Check Shoe Positions Place a flatblade screwdriver under the adjusting arm (1) and raise the arm off of the adjusting wheel (2). While holding the arm (1) up, turn the wheel (2) upward until it stops (Figure 6-17, Page 6-8). Remove the screwdriver. Figure 6-17 Set Adjusting Wheel Install the axle shaft into the transaxle.
Page 83 WHEEL BRAKE ASSEMBLIES Brake Shoe Installation WARNING • Be sure retaining ring is properly seated in groove. If ring is not properly installed, the axle assembly will separate from the transaxle and damage the axle assembly and other components. Loss of vehicle control could result in severe personal injury or death.
Page 84: Brake Cable Equalizer Adjustment
Brake Cable Equalizer Adjustment WHEEL BRAKE ASSEMBLIES BRAKE CABLE EQUALIZER ADJUSTMENT See General Warnings on page 1-2. See also Asbestos Dust Warning on page 6-1. After maintenance on the brake system is complete, lower the vehicle onto the floor. With the brake pedal in the full up or at rest position, adjust the turnbuckle (1) until the proper brake tension is achieved (Figure 6-18, Page 6-9).
Page 85: Brake Cluster Removal And Installation
WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation BRAKE CLUSTER REMOVAL AND INSTALLATION See General Warnings on page 1-2. See also Asbestos Dust Warning on page 6-1. BRAKE CLUSTER REMOVAL Electric Vehicle: Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4.
Page 86 Brake Cluster Removal and Installation WHEEL BRAKE ASSEMBLIES Install the axle shaft into the transaxle. See following NOTE. NOTE: There is a LEFT and RIGHT side axle. The splined portions on the axles that insert into the transaxle case are two different lengths.
Page 87: Brake Cable Removal And Installation
WHEEL BRAKE ASSEMBLIES Brake Cable Removal and Installation BRAKE CABLE REMOVAL AND INSTALLATION See General Warnings on page 1-2. See also Asbestos Dust Warning on page 6-1. BRAKE CABLE REMOVAL Electric Vehicle: Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4.
Page 88: Brake Cable Installation
Brake Cable Removal and Installation WHEEL BRAKE ASSEMBLIES Figure 6-20 Disconnect Cables at Rear Brakes Figure 6-21 Brake Cable Mounting Tab BRAKE CABLE INSTALLATION NOTE: The driver-side and passenger-side brake cables are not interchangeable. The driver-side cable is shorter than the passenger-side cable. Make sure the correct cable is used on the correct side. Be sure to orient the cable so that the clevis end goes to the wheel rather than to the equalizer bracket.
Page 89: Section 7 - Steering And Front Suspension
SECTION 7 – STEERING AND FRONT SUSPENSION DANGER • 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 90: Steering Wheel Installation
Steering Column STEERING AND FRONT SUSPENSION 5.5. Remove the steering wheel from the steering column. 2519 2520 Figure 7-1 Steering Wheel Removal Figure 7-2 Steering Wheel Puller STEERING WHEEL INSTALLATION NOTE: To minimize corrosion and to make future removal of the steering wheel easier, apply a small amount of oil or anti-seize compound to steering shaft before installing the steering wheel.
Page 91: Steering Column Installation
STEERING AND FRONT SUSPENSION Steering Column 2622 Figure 7-3 Steering Column STEERING COLUMN INSTALLATION For ease of assembly and to prevent corrosion, apply a light coat of anti-seize or lubricating compound to the splined stud extending from the steering gear. Insert the end of the steering column with the universal joint through the front underbody.
Page 92: Rack And Pinion
Rack and Pinion STEERING AND FRONT SUSPENSION 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 7-4. The manufacturer recommends inspecting the rack and pinion and replacing if damaged.
Page 93: Rack And Pinion Removal
STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION REMOVAL Electric Vehicle: Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4. Gasoline Vehicle: Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-3.
Page 94: Front Suspension
Front Suspension STEERING AND FRONT SUSPENSION FRONT SUSPENSION See General Warnings on page 1-2. LUBRICATION Two grease fittings are provided (one in each spindle housing). Lubricate these fittings at the recommended interval with the proper lubricant. See Periodic Lubrication Schedules on page 10-7. CAUTION •...
Page 95 STEERING AND FRONT SUSPENSION Front Suspension Figure 7-5 Check Camber Figure 7-6 Adjust Camber Toe-in Adjustment On a level surface, roll the vehicle forward, then stop. Make sure the front wheels are pointed straight ahead. Do not turn the steering wheel again during this procedure. On each front tire, mark (as closely as possible) the center of the tread face that is oriented toward the rear of the vehicle.
Page 96: Front Suspension Components
Front Suspension Components STEERING AND FRONT SUSPENSION 6.2. Rotate both of the drag links equally. To increase the toe-in, rotate both drag links counterclockwise. To decrease the toe-in, rotate both drag links clockwise. Maintain an equal distance from the ball joint to the end of the threads on each drag link (Figure 7-9, Page 7-8).
Page 97: Leaf Spring Removal
STEERING AND FRONT SUSPENSION Front Suspension Components Electric Vehicle: Connect batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Gasoline Vehicle: Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles on page 1-4. LEAF SPRING REMOVAL Electric Vehicle: Disconnect the batteries and discharge the controller.
Page 98: Kingpin And Steering Spindle Installation
Front Suspension Components STEERING AND FRONT SUSPENSION Slide the spindle (3) off the kingpin (7). Remove the wave washer (6) and inspect it. If the washer is broken or has a wave bottom to wave crest height dimension of less than 0.040 inch (1 mm), it must be replaced. Remove bolt (8) from bottom of kingpin (7) and remove kingpin.
Page 99: Control Arm Installation
STEERING AND FRONT SUSPENSION Front Suspension Components CONTROL ARM INSTALLATION Install the control arm in reverse order of removal. Tighten the control arm bolts (11 and 19) to 30 ft·lb (41 N·m) (Figure 7-10, Page 7-12). Tighten three rack and pinion mounting bolts (17) to 22 ft·lb (30 N·m) Install the wheels and adjust the wheel alignment as instructed on page 7-6.
Page 100 Front Suspension Components STEERING AND FRONT SUSPENSION 1311 Figure 7-10 Upper Front Suspension Assembly Page 7-12 2014 Precedent ® Golf Car Maintenance and Service Manual...
Page 101 STEERING AND FRONT SUSPENSION Front Suspension Components 1312 Figure 7-11 Lower Front Suspension Assembly 2014 Precedent ® Golf Car Maintenance and Service Manual Page 7-13...
Page 102: Front Wheel Bearings And Hubs
Front Wheel Bearings and Hubs STEERING AND FRONT SUSPENSION FRONT WHEEL BEARINGS AND HUBS See General Warnings on page 1-2. NOTE: The front wheel bearings are pressed into the spindle and are not serviceable. If excessive free-play is detected the entire hub should be replaced. FRONT WHEEL FREE PLAY INSPECTION Electric Vehicle: Disconnect the batteries and discharge the controller.
Page 103 STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs Figure 7-12 Front Wheel Hub 2014 Precedent ® Golf Car Maintenance and Service Manual Page 7-15...
Page 105: Section 8 - Wheels And Tires
SECTION 8 – WHEELS AND TIRES DANGER • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION Maximum tire life and good vehicle handling qualities are directly related to proper wheel and tire care. •...
Page 106: Tires
Tires WHEELS AND TIRES Lower the vehicle and finish tightening lug nuts, using a crisscross pattern, to 55 ft·lb (74.6 N·m). Electric Vehicle: Connect batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Gasoline Vehicle: Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles on page 1-4.
Page 107: Tire Repair
Small holes in the casing can be plugged using a standard automotive tubeless tire repair kit available at your local Club Car dealer. When the cause of the air leak has been determined, remove tire from the rim and repair as required. See Tire Removal on page 8-2.
Page 108 Tires WHEELS AND TIRES Figure 8-2 Inflate Tire Page 8-4 2014 Precedent ® Golf Car Maintenance and Service Manual...
Page 109: Section 9 - Rear Suspension
SECTION 9 – REAR SUSPENSION DANGER • 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 110: Leaf Springs (Two-Passenger Vehicles)
Leaf Springs (Two-Passenger Vehicles) REAR SUSPENSION LEAF SPRINGS (TWO-PASSENGER VEHICLES) See General Warnings on page 1-2. LEAF SPRING REMOVAL (TWO-PASSENGER VEHICLES) Electric Vehicle: Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4. Gasoline Vehicle: Disconnect battery and spark plug wire(s).
Page 111: Leaf Spring Installation (Two-Passenger Vehicles)
REAR SUSPENSION Leaf Springs (Two-Passenger Vehicles) Figure 9-1 Support Vehicle on Jack Stands Figure 9-2 Disconnect Brake Cable LEAF SPRING INSTALLATION (TWO-PASSENGER VEHICLES) To install the springs, reverse the removal procedure. See following CAUTION. CAUTION • When positioning the spring on the transaxle, be sure to insert the locating bolt on the spring in the locating hole in the transaxle saddle.
Page 112 Leaf Springs (Two-Passenger Vehicles) REAR SUSPENSION 2689 Figure 9-3 Rear Suspension Assembly and Mounting (Two-Passenger Vehicles) Page 9-4 2014 Precedent ® Golf Car Maintenance and Service Manual...
Page 113: Leaf Springs (Four-Passenger Vehicles)
REAR SUSPENSION Leaf Springs (Four-Passenger Vehicles) LEAF SPRINGS (FOUR-PASSENGER VEHICLES) See General Warnings on page 1-2. LEAF SPRING REMOVAL (FOUR-PASSENGER VEHICLES) Electric Vehicle: Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4. Gasoline Vehicle: Disconnect battery and spark plug wire(s).
Page 114 Leaf Springs (Four-Passenger Vehicles) REAR SUSPENSION 2690 Figure 9-4 Rear Suspension Assembly and Mounting (Four-Passenger Vehicles) Page 9-6 2014 Precedent ® Golf Car Maintenance and Service Manual...
Page 115: Leaf Spring Installation (Four-Passenger Vehicles)
REAR SUSPENSION Leaf Springs (Four-Passenger Vehicles) LEAF SPRING INSTALLATION (FOUR-PASSENGER VEHICLES) To install the springs, reverse the removal procedure. See following CAUTION. CAUTION • When positioning the spring on the transaxle, be sure to insert the locating bolt on the spring in the locating hole in the transaxle saddle.
Page 117: Section 10 - Periodic Maintenance
Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service. PRE-OPERATION AND DAILY SAFETY CHECKLIST Each Club Car vehicle has been thoroughly inspected and adjusted at the factory; however, upon receiving your new vehicle(s), you should become familiar with its controls, indicators, and operation. Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery.
Page 118: Performance Inspection
When the pedal is released it should return to the original position. All Club Car vehicles operate at reduced speed in reverse.
Page 119: Maintenance
Any vehicle not functioning correctly should be removed from use until it is properly repaired. This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service. WARNING •...
Page 120: Periodic Service Schedules
Periodic Service Schedules PERIODIC MAINTENANCE PERIODIC SERVICE SCHEDULES WARNING • Service, repairs, and adjustments must be made per instructions in the appropriate section of this manual. • If any problems are found during scheduled inspection or service, do not operate the vehicle until repairs are made.
Page 121 PERIODIC MAINTENANCE Periodic Service Schedules PERIODIC SERVICE SCHEDULE – ELECTRIC VEHICLES REGULAR INTERVAL SERVICE Semiannual service by trained technician Check brake shoes; replace if necessary. only (every 50 hours of operation or 100 Lubricate brake system per Lubrication rounds of golf) Schedule.
Page 122 Periodic Service Schedules PERIODIC MAINTENANCE PERIODIC SERVICE SCHEDULE – GASOLINE VEHICLES REGULAR INTERVAL SERVICE See Pre-Operation and Daily Safety Checklist Pre-Operation and Daily Safety Checklist in the appropriate Owner’s Manual Daily service by owner See Performance Inspection in the appropriate Performance Inspection Owner’s Manual Check engine oil level;...
Page 123: Periodic Lubrication Schedules
PERIODIC MAINTENANCE Periodic Lubrication Schedules PERIODIC SERVICE SCHEDULE – GASOLINE VEHICLES REGULAR INTERVAL SERVICE Check safety decals. Replace if damaged or Safety decals illegible. Two year service by trained technician only (every 200 hours of operation or every 400 Fuel filters Replace.
Page 124 Periodic Lubrication Schedules PERIODIC MAINTENANCE PERIODIC LUBRICATION SCHEDULE – GASOLINE VEHICLES LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Shifter cable pivots Dry Moly Lube (CC P/N 1012151) Semiannually by owner or trained technician (every 50 Brake system, per maintenance and Dry Moly Lube (CC P/N 1012151), white hours of operation or every service manual.
Page 125: Engine Oil - Gasoline Vehicles
PERIODIC MAINTENANCE Engine Oil – Gasoline Vehicles ENGINE OIL – GASOLINE VEHICLES ENGINE OIL LEVEL CHECK Remove the oil level dipstick from the oil filler tube, and wipe oil off dipstick (1) (Figure 10-3). See following CAUTION. CAUTION • Do not remove dipstick while engine is running. Check oil by fully inserting the dipstick into the oil filler tube (2) and immediately removing it.
Page 126 11. Coat new oil filter gasket with clean engine oil, Install the oil filter onto the engine oil filter port (Figure 10-6). NOTE: Use only Club Car oil filters (CC P/N 103887901) designed for this engine. 12. Hand tighten 2/3 to 3/4 turn after filter gasket contacts mounting surface.
Page 127: Oil Viscosity
PERIODIC MAINTENANCE Engine Oil – Gasoline Vehicles 13. Remove the dipstick and add engine oil into the dipstick port. With filter change, the engine requires 38 ounces (1.12 L) of oil per change. Refer to oil viscosity guidelines for selection of oil grade (Figure 10-7). See following Caution.
Page 128 Engine Oil – Gasoline Vehicles PERIODIC MAINTENANCE SAE 30 SAE 10W-30/ SAE 10W-40 SAE 5 W-30 Figure 10-7 Oil Viscosity Chart Page 10-12 2014 Precedent ® Golf Car Maintenance and Service Manual...
Page 129: Section 11 - Iq Display Module (Iqdm) And Iqdm-Pdiagnostics: Excel System With Powerdrive Charger
SECTION 11 – IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH POWERDRIVE CHARGER DANGER • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. NOTE: For information specific to the IQDM-P handset programming features, see IQ Display Module Programmer (IQDM-P): Excel System with PowerDrive Charger on page 12-1.
Page 130: Quick Reference Guide - Excel With Powerdrive Charger
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH Quick Reference Guide – Excel with PowerDrive Charger POWERDRIVE CHARGER QUICK REFERENCE GUIDE – EXCEL WITH POWERDRIVE CHARGER OPERATION: Change screen contrast for better viewing by selecting the following: Programmer Setup, Program, LCD Contrast Preset Favorites: Select a frequently viewed screen, push and hold one of the three yellow keys until the display reads, “1,2,3 Bookmark Set”.
Page 131: Menu Navigation
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH POWERDRIVE CHARGER Menu Navigation • Monitor • Faults • Functions • Information • Programmer Setup In the event that the handset does not display any information, or the screen is difficult to read, refer to the IQDM troubleshooting procedures.
Page 132: Program (Iqdm-P Only)
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH Menu Navigation POWERDRIVE CHARGER The three yellow buttons labeled 1, 2 and 3 are BOOKMARK BUTTONS (4) (Figure 11-3, Page 11-3). These buttons allow the user to bookmark up to three specific screens for rapid return to those screens. To bookmark a specific display screen, have the desired screen displayed and simply press and hold a bookmark button until the statement “bookmark set”...
Page 133: Monitor Menu
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH POWERDRIVE CHARGER Monitor Menu MONITOR MENU The monitor menu is accessed by using the up or down arrow to scroll to monitor and pressing the right arrow key 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: Arm Current
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH Monitor Menu POWERDRIVE CHARGER ARM CURRENT Displays the motor armature current (in amperes). FIELD CURRENT Displays the motor field current (in amperes). ARMATURE PWM Displays motor armature PWM (pulse width modulation). The range of pulse width modulation is 0% to 100%. When the vehicle is operating at full speed, the pulse width modulation should be at 100%.
Page 135: Forward Input
“private speed mode”. In the event that “private speed mode” is locked out, the controller must be removed and shipped to Club Car before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 12-4.
Page 136: Pedal Counters
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH Monitor Menu POWERDRIVE CHARGER PEDAL COUNTERS Accumulates accelerator pedal usage. FAULT COUNTERS The Fault Counters indicate how many times each fault type has been recorded since the last clearing of fault history. See following Faults Menu section.
Page 137: Faults Menu
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH POWERDRIVE CHARGER Faults Menu FAULTS MENU CAUTION • A failed motor will damage the controller. Always inspect the motor before replacing the controller. See External Motor Testing, Section 17, Page 17-1. NOTE: The software is subject to frequent updates, and this manual spans many versions.
Page 138 IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH Faults Menu POWERDRIVE CHARGER The vehicle speed controller should be checked for fault codes before any service is performed. The speed controller, after detecting a fault, will respond in one or more of the following ways: •...
Page 139: Hw Failsafe
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH POWERDRIVE CHARGER Faults Menu Fault Recovery When a fault is detected by the speed controller, the speed controller will attempt to recover from the fault and resume normal operation. In the case of an intermittent problem such as a loose wiring connection, the controller may be able to recover and operate normally for a while, but the problem should be repaired before placing the vehicle in service.
Page 140: Speed Sensor
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH Faults Menu POWERDRIVE CHARGER What it means: If the voltage seen by the controller coming out of the MCOR3 is not within specified limits, this fault occurs. Perform additional diagnostic if vehicle is running. What to do: Replace MCOR3.
Page 141: Fld (Field) Missing
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH POWERDRIVE CHARGER Faults Menu FLD (FIELD) MISSING If the speed controller is operating at a duty cycle of greater than 90% (almost full speed) and the field current is less than 3 amps, a field missing fault is detected by the speed controller.
Page 142: Motor Stall
The max password tries fault is declared when the incorrect password fault has been declared several times. In the event that the max password tries fault is indicated, the speed controller must be removed and shipped to Club Car before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 12-4. See also Password Tries (IQDM-P Only) on page 11-7.
Page 143: M- Shorted
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH POWERDRIVE CHARGER Functions Menu M– SHORTED If an uncontrolled current path is detected from the motor to B- (bypassing the MOSFETs), an M- shorted fault is detected. FAULT HISTORY The fault history menu can be useful in determining the cause of a vehicle problem; however, the fault history alone should not be the factor that determines when a component is replaced.
Page 144: Write Settings To Controller
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH Functions Menu POWERDRIVE CHARGER Scroll to the functions menu and select. Select settings. Select get settings from controller. Press “+” on the change value button to confirm the operation. The handset will display an “executing...” message for the next few seconds while the controller settings are being stored in the handset’s memory (Figure 11-4, Page 11-16).
Page 145 IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH POWERDRIVE CHARGER Functions Menu Turn the key switch to the OFF position, place the Forward/Reverse handle in the NEUTRAL position, and lock the park brake. Plug the handset into the vehicle. 4.1.
Page 146: Reset All Settings
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH Information POWERDRIVE CHARGER RESET ALL SETTINGS In the event that a mistake was made and one or more changes should not have been made with the handset, the speed controller settings can be reverted to the original settings from the beginning of the session (when the handset was plugged into the vehicle).
Page 147: Programmer Setup
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH POWERDRIVE CHARGER Programmer Setup PROGRAMMER SETUP The programmer setup menu selection allows the user to set the LCD display contrast, records the fault history of the handset, and displays information pertaining to the handset. PROGRAM This menu allows the user to adjust the contrast on the display screen.
Page 148: Iqdm And Iqdm-P Handset Troubleshooting
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH IQDM and IQDM-P Handset Troubleshooting POWERDRIVE CHARGER IQDM AND IQDM-P HANDSET TROUBLESHOOTING In the event that the handset does not function as described in this manual, the following troubleshooting guide should be studied and the referenced test procedures should be performed to troubleshoot the handset.
Page 149: Test Procedures
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH POWERDRIVE CHARGER Test Procedures TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Disconnect the IQDM cord from the vehicle. Handset malfunction Wait a few seconds and reconnect the handset to the vehicle See Section 15 –...
Page 150 IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH Test Procedures POWERDRIVE CHARGER The procedure for testing the handset cord adaptor is similar to the cord test. Using a multimeter set for 200 ohms, place the red (+) probe into one of the terminals on the end of the adapter with the square plug.
Page 151 IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH POWERDRIVE CHARGER Test Procedures 4.2. Remove electronics module cover. See Electronics Module Cover on page 14-5. 4.3. Connect IQDM to controller. 4.3.1. Disconnect the square four-pin connector (3) from the speed controller. 4.3.2.
Page 153: Section 12 - Iq Display Module Programmer (Iqdm-P): Excel System With Powerdrive Charger
SECTION 12 – IQ DISPLAY MODULE PROGRAMMER (IQDM-P): EXCEL SYSTEM WITH POWERDRIVE CHARGER DANGER • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. NOTE: For information pertaining to the introductory display, menu navigation, and monitor, faults and function menus, see IQ Display Module (IQDM) and IQDM-P Diagnostics: Excel System with PowerDrive Charger on page 11-1.
Page 154: Program Menu
IQ DISPLAY MODULE PROGRAMMER (IQDM-P): Program Menu EXCEL SYSTEM WITH POWERDRIVE CHARGER PROGRAM MENU The program menu can be accessed by pressing the right arrow on the navigation button when the square beside program is blinking (Figure 12-3, Page 12-2). When the program menu is active, use the up or down arrows on the navigation button to go to the desired item in the program menu.
Page 155: Speed Setting
IQ DISPLAY MODULE PROGRAMMER (IQDM-P): EXCEL SYSTEM WITH POWERDRIVE CHARGER Program Menu SPEED SETTING The vehicle’s top speed can be changed by selecting values 1 through 3 (Figure 12-4, Page 12-2). If a value of 4 is displayed for the speed setting, a special access code has been entered to place the vehicle in “private speed mode.” A speed setting of 4 cannot be selected with the speed setting menu item.
Page 156: S3 Fwd Speed
ANSI Z130.1 – American National Standard for Golf Cars – Safety and Performance Specifications because it is capable of speeds in excess of 15 mph (24.1 km/h). For more information on this feature, contact your local Club Car distributor or dealer. VEHICLE S/N Six digit number programmed by vehicle manufacturer.
Page 157: Section 13 - Excel System Troubleshooting: With Powerdrive Charger
SECTION 13 – EXCEL SYSTEM TROUBLESHOOTING: WITH POWERDRIVE CHARGER DANGER • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. • Shorting of battery terminals can cause personal injury or death. – Do not place component mounting plate directly on top of batteries when removing or installing plate.
Page 158: Features
EXCEL SYSTEM TROUBLESHOOTING: WITH General Information POWERDRIVE CHARGER FEATURES • Shunt-Wound Motor: The shunt-wound motor, unlike a series motor, is designed so that the speed controller is able to vary the amount of current passing through the field coils independently from the current passing through the armature.
Page 159: Wiring Diagrams
EXCEL SYSTEM TROUBLESHOOTING: WITH POWERDRIVE CHARGER Wiring Diagrams WIRING DIAGRAMS WARNING LIGHT PRO GRAMMER PLUG #18 BLACK REVERS E #18 YELLOW BUZZER #16 BLUE #18 GREEN #18 RED #18 BLACK/YELLOW #18 BROWN/WHITE #16 GREEN/RED #18 BROWN/WHITE #18 ORANGE/WHITE #18 RED SW_4 9-PIN CONNECTOR.
Page 160 EXCEL SYSTEM TROUBLESHOOTING: WITH Wiring Diagrams POWERDRIVE CHARGER USED WHEN THERE ARE LIGHTS BUT NO TURN S IGNAL. NORMALLY OPEN MOM ENTARY PUSH BU TTON FOR HORN 9-PIN #16 ORANGE CONNECT OR #16 BLUE/WHITE #16 WHITE #16 YELLOW SONIC #16 BROWN/WHITE WELD FLASHER UNIT...
Page 161 EXCEL SYSTEM TROUBLESHOOTING: WITH POWERDRIVE CHARGER Wiring Diagrams HEADLIGHT ASSEMBLY DC - DC HORN CONVERTER SONIC 20 AMP WELD #16 BLACK FUS E SONIC WELD #18 O RANGE DIODE #16 BLACK/WHITE #12 BLACK SON IC WELD #16 BLACK SON IC WELD CONNE CTS TO MAIN HARNESS.
Page 162 EXCEL SYSTEM TROUBLESHOOTING: WITH Wiring Diagrams POWERDRIVE CHARGER W35 18_GRN SMART BOX W77 16_RED_WHT SW_9 CONNECTOR W39 18_BRN_WHT W10 18_BLK_WHT W13 18_GRAY SW_6 W09 18_BLK W08 18_YEL W102 16_BLU W36 18_GRN W07 18_RED W20 18_YEL_BLK W31 16_LT_GRN W37 18_BRN_WHT W04 18_ORG_WHT SW_8 CONNECTS TO INSTRUMENT...
Page 163 EXCEL SYSTEM TROUBLESHOOTING: WITH POWERDRIVE CHARGER Wiring Diagrams 16_RED_WHT 2-AMP FUSE W91 18_BLU_WHT 10_RED W30 16_PINK 6_ RED SOLENOID 250 OHM CHARGER W66 18_LT_BLU RECEPTACLE ONBOARD COMPU TER W111 18_YEL W29 18_RED W38 18_BRN_WHT P UR W103 18_WHT W06 18_LT_BLU TO (B-) CONTROLLER TO (B-) BATTERY 6_ BLK...
Page 164: Troubleshooting
TROUBLESHOOTING THE VEHICLE WITH THE IQDM Club Car recommends the use of the IQDM handset for troubleshooting vehicles equipped with the Excel electrical system. Troubleshooting Guide 1 is to be used in conjunction with the IQDM handset. See IQ Display Module (IQDM) and IQDM-P Diagnostics: Excel System with PowerDrive Charger on page 11-1 for operating instructions.
Page 165 EXCEL SYSTEM TROUBLESHOOTING: WITH POWERDRIVE CHARGER Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected motor speed sensor Repair and/or connect the three-pin connector or broken wire to the motor speed sensor Test Menu – SPEED PULSES menu item indicates that speed pulses are OFF when Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector...
Page 166 EXCEL SYSTEM TROUBLESHOOTING: WITH Troubleshooting POWERDRIVE CHARGER TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected three-pin connector at Repair and/or connect the three-pin connector the MCOR3 or broken wire to the MCOR Diagnostic Menu – THROTTLE FAULT fault Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector code...
Page 167: Troubleshooting Guide 2
EXCEL SYSTEM TROUBLESHOOTING: WITH POWERDRIVE CHARGER Troubleshooting TROUBLESHOOTING GUIDE 2 TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Batteries – Batteries discharged Charge batteries Check vehicle wiring. See Wiring Diagrams Batteries – Battery connections on page 13-3. Battery charger is connected to the vehicle Disconnect the battery charger from the –...
Page 168 EXCEL SYSTEM TROUBLESHOOTING: WITH Troubleshooting POWERDRIVE CHARGER TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Test Procedure 21 – Motor Speed Sensor on Speed sensor disconnected or failed page 13-34 To change the programmed top speed of the Incorrect speed setting vehicle, an IQDM-P handset must be used Check vehicle wiring.
Page 169: Test Procedures
EXCEL SYSTEM TROUBLESHOOTING: WITH POWERDRIVE CHARGER Test Procedures TEST PROCEDURES Using the following procedures, the entire electrical system can be tested without major disassembly of the vehicle. WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.
Page 170 EXCEL SYSTEM TROUBLESHOOTING: WITH Test Procedures POWERDRIVE CHARGER 21 – Motor Speed Sensor 22 – Solenoid Continuity 23 – Forward/Reverse Rocker Switch 24 – Reverse Buzzer 25 – Rebooting the Onboard Computer 26 – Battery Warning Light TEST PROCEDURE 1 – Batteries / Voltage Check See General Warnings on page 1-2.
Page 171 EXCEL SYSTEM TROUBLESHOOTING: WITH POWERDRIVE CHARGER Test Procedures TEST PROCEDURE 2 – Onboard Computer Solenoid Lockout Circuit See General Warnings on page 1-2. The solenoid lockout circuit disables the vehicle when the battery charger is plugged into the vehicle. Use the following procedure to test the solenoid lockout circuit: With batteries connected, place the Tow/Run switch in the RUN position.
Page 172 EXCEL SYSTEM TROUBLESHOOTING: WITH Test Procedures POWERDRIVE CHARGER – A reading of 200 to 250 ohms should be obtained for factory-installed solenoids (Figure 13-7, Page 13-16). If not, replace the solenoid. – A reading of 180 to 190 ohms should be obtained for service replacement solenoids (Figure 13-8, Page 13-16).
Page 173 EXCEL SYSTEM TROUBLESHOOTING: WITH POWERDRIVE CHARGER Test Procedures Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands under the frame rails just forward of each spring mount. See WARNING “Lift only one end...” in General Warnings on page 1-2.
Page 174 EXCEL SYSTEM TROUBLESHOOTING: WITH Test Procedures POWERDRIVE CHARGER 8.7. With the accelerator pedal fully up (not pressed), the multimeter should indicate between 4.7k ohms and 6.4k ohms. 8.8. Slowly press the accelerator pedal while monitoring the multimeter. The resistance should drop as the pedal is pressed.
Page 175 EXCEL SYSTEM TROUBLESHOOTING: WITH POWERDRIVE CHARGER Test Procedures TEST PROCEDURE 6 – Tow/Run Switch See General Warnings on page 1-2. Tow/Run Switch Test with the IQDM Handset With the Tow/Run switch in the RUN position, connect the IQDM to the vehicle. Immediately after the IQDM is connected to the vehicle, the screen should display a copyright notice and the IQDM model number.
Page 176 EXCEL SYSTEM TROUBLESHOOTING: WITH Test Procedures POWERDRIVE CHARGER TEST PROCEDURE 7 – Battery Pack Voltage (Under Load) See General Warnings on page 1-2. 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 177 EXCEL SYSTEM TROUBLESHOOTING: WITH POWERDRIVE CHARGER Test Procedures 4.1. Access the Test menu and select KEY INPUT by using the SCROLL DISPLAY buttons. The IQDM should indicate OFF when the key switch is in the OFF position. 4.2. While monitoring the IQDM display screen, turn the key switch to the ON position. The IQDM should indicate ON.
Page 178 EXCEL SYSTEM TROUBLESHOOTING: WITH Test Procedures POWERDRIVE CHARGER WARNING • The Forward/Reverse switch must be in the neutral position to avoid personal injury due to contact with rotating wheels. 5.2. With Tow/Run switch in the RUN position, key switch in the ON position, and Forward/Reverse rocker switch in the NEUTRAL position, the voltage reading should be zero volts.
Page 179 EXCEL SYSTEM TROUBLESHOOTING: WITH POWERDRIVE CHARGER Test Procedures SPEED CONTROLLER 16-PIN CONNECTOR WIRE TEST PROCEDURE Pin 1 – White (18-gauge) Test Procedure 10 – Pins 1, 2, and 3 on page 13-23 Pin 2 – Yellow (18-gauge) Also for Pin 3 Test continuity of wire and perform Test Procedure 21 – Motor Speed Sensor on page 13-34 Pin 3 –...
Page 180 EXCEL SYSTEM TROUBLESHOOTING: WITH Test Procedures POWERDRIVE CHARGER WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 20k Ohm Setting (reading with pedal not pressed) Figure 13-10 Pins 1, 2, and 3 Test Using a multimeter set for 20k ohms, insert the red (+) probe of the multimeter into pin 2 (yellow wire) at the 16-pin connector.
Page 181 EXCEL SYSTEM TROUBLESHOOTING: WITH POWERDRIVE CHARGER Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with OBC powered-up and battery charger disconnected) Figure 13-11 Pin 5 Test Place the Tow/Run switch in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4.
Page 182 EXCEL SYSTEM TROUBLESHOOTING: WITH Test Procedures POWERDRIVE CHARGER WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with OBC powered-up and accelerator pedal pressed) Figure 13-12 Pin 6 Test Using a multimeter set for 200 volts DC, insert the red (+) probe of the multimeter into pin 6 (green wire) of the 16-pin connector.
Page 183 EXCEL SYSTEM TROUBLESHOOTING: WITH POWERDRIVE CHARGER Test Procedures TEST PROCEDURE 13 – Pin 7 See General Warnings on page 1-2. Pin 7 in the 16-pin connector provides a connection point for the reverse buzzer to the speed controller. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4.
Page 184 EXCEL SYSTEM TROUBLESHOOTING: WITH Test Procedures POWERDRIVE CHARGER TEST PROCEDURE 14 – Pins 8 and 16 See General Warnings on page 1-2. Pins 8 and 16 in the 16-pin connector provide a connection point for the Forward/Reverse rocker switch to the speed controller.
Page 185 EXCEL SYSTEM TROUBLESHOOTING: WITH POWERDRIVE CHARGER Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with Tow/Run switch in RUN and Forward/Reverse switch in FORWARD) Figure 13-14 Pins 8 and 16 Test TEST PROCEDURE 15 – Pin 9 See General Warnings on page 1-2.
Page 186 EXCEL SYSTEM TROUBLESHOOTING: WITH Test Procedures POWERDRIVE CHARGER WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with Tow/Run switch in RUN position) Figure 13-15 Pin 9 Test With the Tow/Run switch in the RUN position, the multimeter should indicate full battery voltage (approximately 48 volts).
Page 187 EXCEL SYSTEM TROUBLESHOOTING: WITH POWERDRIVE CHARGER Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with Tow/Run switch in RUN and key switch in the ON position) Figure 13-16 Pin 10 Test Place the Tow/Run switch in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4.
Page 188 EXCEL SYSTEM TROUBLESHOOTING: WITH Test Procedures POWERDRIVE CHARGER CAUTION • Do not fully insert probes into the 16-pin plug. Doing so can result in a poor connection. Place the Tow/Run switch in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4.
Page 189 EXCEL SYSTEM TROUBLESHOOTING: WITH POWERDRIVE CHARGER Test Procedures – Black wire terminal socket in the charger receptacle. – Onboard computer gray wire. See Test Procedure 19 – Onboard Computer Gray Wire on page 13-33. – Red wire at the charger receptacle. See Test Procedure 20 – Voltage at Charger Receptacle Red Wire Socket on page 13-33.
Page 190 EXCEL SYSTEM TROUBLESHOOTING: WITH Test Procedures POWERDRIVE CHARGER TEST PROCEDURE 21 – Motor Speed Sensor See General Warnings on page 1-2. Motor Speed Sensor Test with the IQDM Handset CAUTION • Perform the following procedure only on a level surface. To avoid injury or property damage, ensure that the path of the vehicle is clear before pushing vehicle.
Page 191 EXCEL SYSTEM TROUBLESHOOTING: WITH POWERDRIVE CHARGER Test Procedures Reconnect the three-pin connector at the motor speed sensor. Using a multimeter set to 20 volts DC, place the black (–) probe on the battery no. 6 (6 x 8-Volt battery set) negative post and place the red (+) probe (with insulation-piercing probe) on the green wire between the three-pin connector and the motor speed sensor.
Page 192 EXCEL SYSTEM TROUBLESHOOTING: WITH Test Procedures POWERDRIVE CHARGER 3.2. Place the Forward/Reverse switch in the FORWARD position. The IQDM should indicate that FORWARD INPUT is ON. If the IQDM indicates any other reading, check vehicle wiring. See Wiring Diagrams on page 13-3.
Page 193: Battery Warning Light
EXCEL SYSTEM TROUBLESHOOTING: WITH POWERDRIVE CHARGER Battery Warning Light 7.1. If the voltage reading is correct, replace the reverse buzzer. 7.2. If reading is zero volts, check orange/white wire continuity and connection at Pin 7 in 16-Pin connector. 7.3. If there is no continuity in the orange/white wire, or the Pin 7 terminal in the 16-Pin connector is not properly seated, repair or replace as required.
Page 194: Communication Display Module (Cdm)
16 hours and the batteries are not sufficiently charged. This indicates an abnormal charge cycle. The charger and batteries should be checked by your Club Car distributor/dealer. • The battery warning light will repeatedly illuminate for 10 seconds, at 4 second intervals, during a charge cycle (with the DC plug still connected) if AC power to the charger is interrupted.
Page 195: Using The Cdm To Retrieve Data From The Onboard Computer
EXCEL SYSTEM TROUBLESHOOTING: WITH POWERDRIVE CHARGER Communication Display Module (CDM) • F2 – Amp hours removed since last charge cycle: • If the display reads over 75 (the vehicle battery warning light should be illuminated), the vehicle batteries need to be recharged before being used again. This data can be used to make sure all vehicles in a fleet receive equal usage on a short-term basis.
Page 196: Cdm Troubleshooting Guide
NOTE: The values of all four functions can be recalled by pressing and releasing the CDM button. CDM TROUBLESHOOTING GUIDE Use the following chart as a starting point for troubleshooting problems with communication between the CDM and onboard computer. Contact your Club Car representative for more comprehensive information. OBC Will Not Communicate With The CDM...
Page 197: Section 14 - Electrical Components: Electric Vehicle With Powerdrive Charger
SECTION 14 – ELECTRICAL COMPONENTS: ELECTRIC VEHICLE WITH POWERDRIVE CHARGER DANGER • 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 the appropriate troubleshooting section for the type of electrical system used in the vehicle. See Excel System Troubleshooting: with PowerDrive Charger on page 13-1.
Page 198: Battery Warning Light
ELECTRICAL COMPONENTS: ELECTRIC Battery Warning Light VEHICLE WITH POWERDRIVE CHARGER 3.3. Secure instrument panel to the dash assembly with three screws (1). Tighten screws to 1.8 ft·lb (2.5 N·m). Connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4. Figure 14-1 Instrument Panel Removal Figure 14-2 Key Switch BATTERY WARNING LIGHT...
Page 199: Battery Warning Light Installation
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE WITH POWERDRIVE CHARGER Forward/Reverse Rocker Switch BATTERY WARNING LIGHT INSTALLATION Install in reverse order of removal. Place the Tow/Run switch in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4. Figure 14-3 Battery Warning Light FORWARD/REVERSE ROCKER SWITCH See General Warnings on page 1-2.
Page 200: Forward/Reverse Rocker Switch Installation
ELECTRICAL COMPONENTS: ELECTRIC Forward/Reverse Rocker Switch VEHICLE WITH POWERDRIVE CHARGER Figure 14-4 Forward/Reverse Rocker Switch FORWARD/REVERSE ROCKER SWITCH INSTALLATION Route the three wires through bezel. Connect the blue (4), orange (5) and brown (6) wires to the rocker switch (3), exactly as shown in (Figure 14-4, Page 14-4). Orient the rocker switch (3) so the terminals are towards the front of the housing (1).
Page 201: Electronics Module Cover
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE WITH POWERDRIVE CHARGER Electronics Module Cover ELECTRONICS MODULE COVER See General Warnings on page 1-2. The electronics module cover needs to be removed to gain access to the speed controller, Tow/Run switch, and onboard computer. ELECTRONICS MODULE COVER REMOVAL Disconnect the batteries and discharge the controller.
Page 202: Tow/Run Switch
ELECTRICAL COMPONENTS: ELECTRIC Tow/Run Switch VEHICLE WITH POWERDRIVE CHARGER Figure 14-5 Access and Remove Electronics Module Cover TOW/RUN SWITCH See General Warnings on page 1-2. TESTING THE TOW/RUN SWITCH See Test Procedure 6 – Tow/Run Switch on page 13-19. TOW/RUN SWITCH REMOVAL Disconnect the batteries and discharge the controller.
Page 203: Motor Controller Output Regulator 3 (Mcor3)
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE WITH POWERDRIVE CHARGER Motor Controller Output Regulator 3 (MCOR3) Return electronics module to its original location and secure with bolt (11) (Figure 14-8, Page 14-11). Tighten bolt to 40 in·lb (4.5 N·m). Place the Tow/Run switch in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4.
Page 204: Reverse Buzzer
ELECTRICAL COMPONENTS: ELECTRIC Reverse Buzzer VEHICLE WITH POWERDRIVE CHARGER Connect the two-pin and three-pin connectors from the wire harness to the MCOR3. Install the pedal group. See Pedal Group Installation on page 5-3. Connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4. REVERSE BUZZER See General Warnings on page 1-2.
Page 205: Electronics Module
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE WITH POWERDRIVE CHARGER Electronics Module (Viewed from underside of instrument panel) A. Pink B. Orange/White Figure 14-7 Reverse Buzzer ELECTRONICS MODULE See General Warnings on page 1-2. While it is not necessary to remove the electronics module from the vehicle, access to individual components may be easier with the module removed.
Page 206: Electronics Module Installation
ELECTRICAL COMPONENTS: ELECTRIC Electronics Module VEHICLE WITH POWERDRIVE CHARGER WARNING • Shorting of battery terminals can cause personal injury or death. – Do not place component mounting plate directly on top of batteries when removing or installing plate. – Remove plate from vehicle completely. ELECTRONICS MODULE INSTALLATION Return electronics module to its location in vehicle but leave it tilted forward.
Page 207 ELECTRICAL COMPONENTS: ELECTRIC VEHICLE WITH POWERDRIVE CHARGER Electronics Module Figure 14-8 Electronics Module Removal 2014 Precedent ® Golf Car Maintenance and Service Manual Page 14-11...
Page 208: Speed Controller
ELECTRICAL COMPONENTS: ELECTRIC Speed Controller VEHICLE WITH POWERDRIVE CHARGER SPEED CONTROLLER See General Warnings on page 1-2. TESTING THE SOLID STATE SPEED CONTROLLER See Test Procedure 5 – A1 and A2 Motor Voltage on page 13-18. SPEED CONTROLLER REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4.
Page 209: Solenoid
WITH POWERDRIVE CHARGER Solenoid 8.6. Select Information, Software Version and verify the value is 13 or higher. If not, contact a Club Car Technical Representative. 8.7. Place the Tow/Run switch in the TOW position for 30 seconds. Then return it to RUN.
Page 210: Onboard Computer (Obc)
ELECTRICAL COMPONENTS: ELECTRIC Onboard Computer (OBC) VEHICLE WITH POWERDRIVE CHARGER Place the Tow/Run switch in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4. ONBOARD COMPUTER (OBC) See General Warnings on page 1-2. TESTING THE ONBOARD COMPUTER See Test Procedure 2 –...
Page 211: Charger Receptacle
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE WITH POWERDRIVE CHARGER Charger Receptacle CHARGER RECEPTACLE See General Warnings on page 1-2. The charger cord, plug, and receptacle are wear items and should be inspected daily. Visually inspect them for cracks, loose connections, and frayed wiring; they must be replaced when worn or damaged. If charger plug or receptacle show signs of corrosion or the plug is difficult to insert or remove, the receptacle contacts and plug terminals should be cleaned with a good electrical contact cleaner or lightly sprayed with WD-40 ®...
Page 212: Charger Receptacle Installation
ELECTRICAL COMPONENTS: ELECTRIC Charger Receptacle VEHICLE WITH POWERDRIVE CHARGER Disconnect the gray wire from the OBC. Remove the three screws (1) that secure the charger receptacle (2) to the bucket. CHARGER RECEPTACLE INSTALLATION Insert the wires through the hole in the bucket (Figure 14-9, Page 14-15). Insert receptacle (2) into bucket.
Page 213: Section 15 - Batteries: Electric Vehicle With Powerdrive Charger
SECTION 15 – BATTERIES: ELECTRIC VEHICLE WITH POWERDRIVE CHARGER DANGER • 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 - 8 Volt
BATTERIES: ELECTRIC VEHICLE WITH Battery Testing Basics – 8 Volt POWERDRIVE CHARGER BATTERY TESTING BASICS – 8 VOLT See General Warnings on page 1-2. OBSERVATION Inspect the battery compartment for the following items: • Rusted, corroded, or broken battery posts •...
Page 215: Battery Testing - 8 Volt
BATTERIES: ELECTRIC VEHICLE WITH POWERDRIVE CHARGER Battery Testing – 8 Volt BATTERY TESTING – 8 VOLT See General Warnings on page 1-2. Three tests have been developed to help diagnose problems with batteries that have not performed as expected. Because each test becomes progressively more detailed and time-consuming, begin with the first test and proceed with each additional test until the problem has been identified.
Page 216 BATTERIES: ELECTRIC VEHICLE WITH Battery Testing – 8 Volt POWERDRIVE CHARGER Performing the Hydrometer Test 1.250 1.280 View at eye level. Figure 15-2 Hydrometer Test Remove the vent cap. If using the digital refractometer (CC P/N AM1285701), follow manufacturer’s directions. If using the hydrometer (CC P/N 1011478), proceed with the following steps.
Page 217 BATTERIES: ELECTRIC VEHICLE WITH POWERDRIVE CHARGER Battery Testing – 8 Volt EXAMPLE OF A HYDROMETER TEST ELEC- CORRECTED SPECIFIC GRAVITY VEHI- BAT- CORREC- TROLYTE REQUIRED TERY TION TEMPERA- ACTION CELL 1 CELL 2 CELL 3 CELL 4 FACTOR TURE 1.275 – 1.280 –...
Page 218: Discharge Test
BATTERIES: ELECTRIC VEHICLE WITH Battery Testing – 8 Volt POWERDRIVE CHARGER DISCHARGE TEST NOTE: Discharge time is dependent on electrolyte temperature. Note and record electrolyte temperature before performing the Discharge Test. Calculate the Discharge Time to Shut-Off Point for the specific set of batteries being tested.
Page 219: Battery Regrouping
BATTERY REGROUPING 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 220 BATTERIES: ELECTRIC VEHICLE WITH Battery Regrouping POWERDRIVE CHARGER BATTERY REGROUPING PROCESS FLOW (6 volt, 8 volt, and 12 volt batteries) 1. In s ta ll a ll n e w b a tte rie s o r a ll re g ro u p a b le b a tte rie s ; d o n o t m ix n e w with re g ro u p a b le e xc e p t fo r th e la s t c a r re g ro u p e d .
Page 221: Battery Replacement
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. 2014 Precedent ®...
Page 222 Outlined below are four battery watering procedures, grouped into two categories: Preferred and Alternate methods. Club Car recommends the use of a deionizer or distilled water. Alternate methods of reverse osmosis or tap water are allowable but should be avoided since water quality can change from day to day depending on additives, water main leaks, etc.
Page 223: Battery Care - Vehicles Equipped With The Single-Point Watering System
BATTERIES: ELECTRIC VEHICLE WITH POWERDRIVE CHARGER Battery Care ALLOWABLE CONTENT (PARTS IMPURITY EFFECTS OF IMPURITY PER MILLION) Nickel None allowed Intense lowering of on-charge voltage Nitrates 10.0 Increased sulfation of negative plate Plate corrosion, loss of capacity, Nitrites reduced life Violent self-discharge, lower Platinum None allowed...
Page 224: Battery Care - Vehicles Without The Single-Point Watering System
BATTERIES: ELECTRIC VEHICLE WITH Battery Care POWERDRIVE CHARGER on page 10-4. If a valve fails to open, the cell will eventually dry out. The initial one-time inspection of all cells will identify any occurrence of a valve that fails to open. If a valve fails to close, it will become evident due to the cell overflowing during routine watering.
Page 225: Self-Discharge
BATTERIES: ELECTRIC VEHICLE WITH POWERDRIVE CHARGER Battery Care SELF-DISCHARGE Contaminants on dirty batteries can provide a path for a small current draw that can slowly discharge batteries, thus wasting valuable energy. To prevent self-discharge, batteries should always be kept clean. Hot weather also has an effect on a battery’s self-discharge rate.
Page 226: Single Point Watering System (Spws)
A deionizer for vehicles with SPWS, Club Car Part Number AM1240701 (110/115 volt AC), is available from Service Parts. Replacement cartridge: AM1240801. Bottled distilled water, with hand pump, Club Car Part Number AM1238501, is recommended for private consumer applications.
Page 227 BATTERIES: ELECTRIC VEHICLE WITH POWERDRIVE CHARGER Single Point Watering System (SPWS) Connect the purger (5) to the female coupler (8) on the hose-end assembly (Figure 15-7, Page 15-15). Figure 15-6 Connecting Hose with Filter to Water Source Figure 15-7 Checking the Water Flow Rate Completely open the water faucet until the water flows out of the hose-end assembly (3), and note the movement of the red flow indicator balls (6).
Page 228: Powerdrive Battery Charger (Ferroresonant)
WARNING • Only trained technicians should repair or service the charger. Contact your nearest Club Car distributor/dealer. • Each charger should have its own dedicated 15 or 20 ampere separately protected (circuit breaker or fuse) single phase branch circuit, in accordance with all applicable electrical codes for the location.
Page 229 BATTERIES: ELECTRIC VEHICLE WITH POWERDRIVE CHARGER PowerDrive Battery Charger (Ferroresonant) WARNING • Do not expose to rain or any liquid. Keep the charger dry. • Never push objects of any kind into the charger through cabinet slots. They may touch dangerous voltage points or cause an electrical short circuit that could result in fire or electrical shock.
Page 230: Charging Batteries
When inserting the DC plug, align the raised guide on the plug with the guide slot in the receptacle and push straight in slowly. Club Car battery chargers interact with the vehicle’s onboard computer. The computer records the amount of energy consumed during vehicle use. While the charger is plugged in, the vehicle’s control circuit is locked out, preventing operation of the vehicle as well as the possibility of consequent damage to the charger and the vehicle.
Page 231: Plug And Receptacle
Batteries should be put on charge even if they have been used for only a short period (10 minutes). The charger is automatic and will turn off when batteries are fully charged. If the charger does not seem to be operating properly, or if the batteries seem weak, contact your local Club Car distributor/dealer. PLUG AND RECEPTACLE The charger cord, plug, and receptacle are wear items and should be inspected daily.
Page 232: Early Excessive Discharging
BATTERIES: ELECTRIC VEHICLE WITH Battery Storage POWERDRIVE CHARGER charger will be allowed to shut off automatically). Placing the batteries on charge after each use reduces the depth of discharge and prolongs battery life. EARLY EXCESSIVE DISCHARGING When vehicle batteries are new, they do not reach their full capacity until they have been discharged and recharged 50 to 70 times.
Page 233: Section 16 - Battery Charger: Powerdrive
SECTION 16 – BATTERY CHARGER: POWERDRIVE Refer to the appropriate battery charger maintenance and service manual. 2014 Precedent ® Golf Car Maintenance and Service Manual Page 16-1...
Page 235: General Information
The vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. The shunt-wound motor is designed for use in Excel System vehicles. 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 236 External Motor Testing MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE MOTOR TERMINALS CONTINUITY TEST RESULT A2 to F1 No Continuity A2 to F2 A1 to Ground No Continuity A2 to Ground F1 to Ground No Continuity F2 to Ground TEST PROCEDURE 1 – Internal Short Circuits See General Warnings on page 1-2.
Page 237: External Motor Testing
MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE External Motor Testing bad connections at the terminals may be the cause. The motor will need to be removed from the vehicle and repaired by a qualified technician. See Motor Removal on page 17-4. If reading is correct, reconnect the motor wires. See Motor Installation on page 17-15. Connect the batteries.
Page 238: Motor
Motor MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE MOTOR See General Warnings on page 1-2. MOTOR REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. Disconnect wires from the terminals on the motor using two wrenches to prevent posts from turning. Label the wires to ensure proper reconnection.
Page 239: Motor Disassembly
MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE Motor Figure 17-3 Lower Axle Remove the bolts and lock washers that secure the motor to the transaxle (Figure 17-24, Page 17-17). 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 240 Motor MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE 2.2. Remove the screw securing the magnet to the armature shaft (Figure 17-4, Page 17-5). 2.3. Inspect the speed sensor magnet. See Speed Sensor Magnet Inspection on page 17-11. Loosen, but do not remove, the two screws securing the end cap to the motor frame (Figure 17-5, Page 17-5). Figure 17-6 End Cap Disengagement Figure 17-7 End Cap Removal Orient the motor so that the splined end of the armature is facing down.
Page 241 MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE Motor 9.1. Place the end cap in a press with the armature facing down. 9.2. Place a bearing press tool with an outer diameter smaller than that of the armature shaft between the press ram and the armature shaft (Figure 17-8, Page 17-7). 9.3.
Page 242: Motor Component Testing And Inspection
Motor Component Testing and Inspection MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE Figure 17-10 Brush Rigging Figure 17-11 Bearing Retaining Ring 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 on page 17-4. Remove the end cap and armature by performing steps 1 through 7 of Motor Disassembly on page 17-5.
Page 243 MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE Motor Component Testing and Inspection CAUTION • Do not use emery cloth to polish the commutator. Particles of emery are conductive and may short-circuit the commutator bars. Do not use oil or lubricants on the commutator or brushes. NOTE: Oil on the commutator may indicate a faulty transaxle input shaft oil seal.
Page 244: Motor Frame And Field Windings Inspection
Motor Component Testing and Inspection MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE MOTOR FRAME AND FIELD WINDINGS INSPECTION Remove the motor from the vehicle. See Motor Removal on page 17-4. Remove the and cap and armature by performing steps 1 through 7 of Motor Disassembly on page 17-5. Burned or scorched insulation on the field windings indicates the motor has overheated due to overloads or grounded or shorted coil windings.
Page 245 MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE Motor Component Testing and Inspection Bearing Inspection NOTE: Replacement of the end cap bearing is highly-recommended if the end cap is removed from the motor. The following procedure is provided as a guideline for determining general bearing failure. Remove the motor from the vehicle.
Page 246 Motor Component Testing and Inspection MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE 2613 Figure 17-15 Electric Motor (EJ8-4001A) Page 17-12 2014 Precedent ® Golf Car Maintenance and Service Manual...
Page 247: Reconditioning The Motor
MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE 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 248 Motor Assembly MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE Figure 17-16 Brush Rigging Figure 17-17 Retracted Brushes Figure 17-18 Armature Installation Figure 17-19 Brush Setting With the brushes retracted, use an arbor press to press the armature shaft into the end cap bearing (Figure 17-18, Page 17-14).
Page 249: Motor Installation
MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE Motor Installation 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. Wipe input shaft with a clean cloth. 1.3.
Page 250 Motor Installation MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE When the motor is pushed onto the input shaft, the motor housing will not bottom out against the transaxle housing (Figure 17-15, Page 17-12). There will be approximately 1/16 inch (1.6 mm) gap between the motor adapter ring and transaxle housing as shown (Figure 17-23, Page 17-16).
Page 251 MOTOR (MODEL EJ8-4001A): ELECTRIC VEHICLE Motor Installation 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. Insert the mounting bolts through the spring shackles and the bushings in the leaf spring eyes and install lock nuts.
Page 253: Section 18 - Transaxle: Electric Vehicle
SECTION 18 – TRANSAXLE: ELECTRIC VEHICLE DANGER • 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 18-5, Page 18-3).
Page 254 Axle Bearing and Shaft TRANSAXLE: ELECTRIC VEHICLE CAUTION • Do not scar or damage the inside surfaces of the tube when removing the oil seal and adapter ring. A damaged tube might have to be replaced. NOTE: Do not discard the adapter ring. If the adapter ring is lost or damaged, the axle tube will have to be replaced. Varying rear axle configurations have been installed on vehicles.
Page 255 TRANSAXLE: ELECTRIC VEHICLE Axle Bearing and Shaft Figure 18-5 Transaxle – Type G 2014 Precedent ® Golf Car Maintenance and Service Manual Page 18-3...
Page 256: Axle Bearing
Axle Bearing and Shaft TRANSAXLE: ELECTRIC VEHICLE 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 18-3, Page 18-2). 1.2. Place a new seal (15) in the adapter ring with the seal lip facing toward the adapter ring lip (Figure 18-3, Page 18-2).
Page 257: Transaxle Removal
TRANSAXLE: ELECTRIC VEHICLE Transaxle Removal TRANSAXLE REMOVAL See General Warnings on page 1-2. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4. Place chocks at the front wheels and slightly loosen lug nuts on both rear wheels. See WARNING “Lift only one end...”...
Page 258 Transaxle Removal TRANSAXLE: ELECTRIC VEHICLE 2700 Figure 18-8 Disconnect Shocks Figure 18-9 Shackles 12. If a floor jack was used, pull floor jack from beneath the transaxle and allow the springs to rest on the floor. 13. Remove the U-bolts attaching the transaxle to the leaf springs (Figure 18-10, Page 18-6). 14.
Page 259: Transaxle Disassembly, Inspection, And Assembly
TRANSAXLE: ELECTRIC VEHICLE Transaxle Disassembly, Inspection, and Assembly 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 18-5, Page 18-3). Remove 11 bolts (24) that hold housing together.
Page 260 Transaxle Disassembly, Inspection, and Assembly TRANSAXLE: ELECTRIC VEHICLE Disassemble the differential gear case: 8.1. Remove the hex bolts (33) and the ring gear (32) from the differential case (Figure 18-5, Page 18-3). 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 18-13, Page 18-8).
Page 261: Transaxle Assembly
TRANSAXLE: ELECTRIC VEHICLE Transaxle Disassembly, Inspection, and Assembly 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 18-5, Page 18-3).
Page 262: Transaxle Installation
Transaxle Installation TRANSAXLE: ELECTRIC VEHICLE WARNING • Be sure retaining ring is properly seated in its groove. If ring is not properly installed, the axle assembly will separate from the transaxle and damage the axle assembly and other components. Loss of vehicle control could result in severe personal injury or death.
Page 263 TRANSAXLE: ELECTRIC VEHICLE Transaxle Installation WARNING • Make sure that the vehicle operates in the reverse direction when the Forward/Reverse switch is in the REVERSE position. The reverse buzzer will sound as a warning when the Forward/Reverse switch is in REVERSE. •...
Page 265: Section 19 - Troubleshooting And Electrical System (Gasoline Vehicle)
SECTION 19 – TROUBLESHOOTING AND ELECTRICAL SYSTEM (GASOLINE VEHICLE) DANGER • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION This section contains the information required to correctly troubleshoot the vehicle. A troubleshooting guide is provided for general troubleshooting.
Page 266 TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM (GASOLINE VEHICLE) TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Spark plug is fouled or in poor condition See Section 21 – AS26 FE 350 Engine. Spark plug wire is damaged or loose See Section 21 – AS26 FE 350 Engine. See Section 19 –...
Page 267 TROUBLESHOOTING AND ELECTRICAL SYSTEM (GASOLINE VEHICLE) Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Exhaust valve is restricted with carbon deposit See Section 21 – AS26 FE 350 Engine. Muffler or exhaust pipe restricted with carbon See Section 23 – Exhaust System. or other substance See Section 19 –...
Page 268 TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM (GASOLINE VEHICLE) TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Test Procedure 7 – Neutral Lockout Limit Neutral lockout cam is in the wrong position Switch on page 19-19 Fuse is blown Test Procedure 2 – Fuse on page 19-14 Battery is dead Test Procedure 1 –...
Page 269 TROUBLESHOOTING AND ELECTRICAL SYSTEM (GASOLINE VEHICLE) Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Engine mounting nuts or bolts are loose See Section 21 – AS26 FE 350 Engine. Snubber on frame is worn or damaged See Section 21 – AS26 FE 350 Engine. Misaligned muffler mounting clamp See Section 23 –...
Page 270: Wiring Diagrams - Throttle Position Sensor (Tps)
TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams – Throttle Position Sensor (TPS) SYSTEM (GASOLINE VEHICLE) WIRING DIAGRAMS – THROTTLE POSITION SENSOR (TPS) 16_BLK_WHT( W43) #18 BLK LEFT #18 BRN 16_WHT( W 04) TAIL L IGHT #18 RED 18_ORG(W13) CONNECTS 3-PIN 16_BLK( W 23) Sonic_8 TO 9-PIN 16_BLK_WHT( W28)
Page 271 TROUBLESHOOTING AND ELECTRICAL SYSTEM (GASOLINE VEHICLE) Wiring Diagrams – Throttle Position Sensor (TPS) FUEL GUAGE SENDING UNIT 10_BLK(W29) FRAME GR OUND OIL SENDING UNIT 10_BLK(W30) ENGINE KIL L HOOK UP ENGINE GR OUND FORWARD & REVERSE LI M IT SWITCHES 16_ORG(W11) 6_RE D(W19) 6_WHT(W32)
Page 272 TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams – Throttle Position Sensor (TPS) SYSTEM (GASOLINE VEHICLE) USED WHEN THERE ARE LIGHTS BUT NO TURN S IGNAL. NORMALLY OPEN MOM ENTARY PUSH BU TTON FOR HORN 9-PIN #16 ORANGE CONNECT OR #16 BLUE/WHITE #16 WHITE #16 YELLOW SONIC #16 BROWN/WHITE...
Page 273 TROUBLESHOOTING AND ELECTRICAL SYSTEM (GASOLINE VEHICLE) Wiring Diagrams – Throttle Position Sensor (TPS) HEADLIGHT ASSEMBLY HORN SONIC WELD #16 BLACK SONIC WELD #12 BLACK #12 BLUE Voltage Limiter #18 O RANGE DIODE DIODE SON IC WELD #16 BLACK/WHITE #16 BLACK SON IC WELD #16 BROWN/WHITE...
Page 274 TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams – Throttle Position Sensor (TPS) SYSTEM (GASOLINE VEHICLE) FUEL GAUGE KEY SWITCH OIL LIGHT #18 BLUE 9-PIN CONNECTOR. CONNECTS TO MAIN HARNESS. SEE FIGURES 11-1 AND 11-2. #18 YELLOW/WHITE #18 BLUE #16 RED #16 RED #18 YELLOW #18 ORANGE #18 RED/WHITE...
Page 275: Electrical System
TROUBLESHOOTING AND ELECTRICAL SYSTEM (GASOLINE VEHICLE) Electrical System ELECTRICAL SYSTEM The electrical system on the gasoline vehicle is 12 volts DC with negative (–) ground to frame, and consists of nine circuits that are easily identified: • Starter Circuit • Generator Circuit •...
Page 276 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM (GASOLINE VEHICLE) 25 – Hour Meter TEST PROCEDURE 1 – Battery See General Warnings on page 1-2. DANGER • Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working around a battery.
Page 277 TROUBLESHOOTING AND ELECTRICAL SYSTEM (GASOLINE VEHICLE) Test Procedures When the float rises off the bottom, adjust the electrolyte level so that the float rides free of the bottom but does not strike the bottom of the rubber bulb. Remove the hydrometer from the cell and release the pressure from the bulb. Hold the hydrometer vertically, ensuring that the float is not contacting the sides of the glass tube.
Page 278 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM (GASOLINE VEHICLE) NOTE: A fully charged battery that is in good condition should have a specific gravity of at least 1.225 in all cells, and the difference in the specific gravity of any two cells should be less than 50 points. Open circuit voltage should be at least 12.4 volts.
Page 279 TROUBLESHOOTING AND ELECTRICAL SYSTEM (GASOLINE VEHICLE) Test Procedures 2418 Figure 19-8 Fuse TEST PROCEDURE 3 – Ground Cables See General Warnings on page 1-2. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-3. Check the starter/generator ground cable.
Page 280 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM (GASOLINE VEHICLE) 4.1. Four 10-gauge black wires are crimped together and connected to the negative (–) battery post. One of these wires is connected via a single position in-line connector to the frame. The frame connection should be clean and tight.
Page 281 TROUBLESHOOTING AND ELECTRICAL SYSTEM (GASOLINE VEHICLE) Test Procedures WHITE / BLACK BLUE WAVETEK 1000 2000 200k 200mA 1000 --- FUSED 750V KEY SWITCH STARTER CIRCUIT 2422 Figure 19-13 Test Key Switch – Engine Starter Circuit TEST PROCEDURE 5 – Throttle Position Sensor (TPS) The throttle position sensor performs the function of two limit switches: the accelerator pedal limit switch and the kill limit switch.
Page 282 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM (GASOLINE VEHICLE) See General Warnings on page 1-2. The black and white/black wires connect to the kill limit switch function of the throttle position sensor. This is the normally closed (NC) portion of the circuit used to ground the ignition and shut the engine off when the pedal is released. NOTE: Keep the battery connected while performing this test procedure.
Page 283 TROUBLESHOOTING AND ELECTRICAL SYSTEM (GASOLINE VEHICLE) Test Procedures WAVETEK WAVETEK 1000 1000 2000 2000 200k 200k 200mA 200mA 1000 --- FUSED 1000 --- 750V FUSED 750V 2425 2426 Figure 19-15 Solenoid Continuity Test Figure 19-16 Solenoid Ground Test Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles on page 1-4. Place the Forward/Reverse handle in NEUTRAL, and place the neutral lockout cam in the MAINTENANCE position.
Page 284 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM (GASOLINE VEHICLE) WAVETEK WAVETEK 1000 1000 2000 2000 200k 200k 200nA 200nA 1000 --- 1000 --- FUSED FUSED 750V 750V 1. Lever Up 2. Lever Depressed 3. Tester light is OFF. Meter reads 1. 4. Tester light is ON. Meter reads approx. zero ohms. Figure 19-17 Test Neutral Lockout Switch Check to be sure the lobes on the cam are pressing the neutral lockout limit switch as the Forward/Reverse handle is being shifted.
Page 285 TROUBLESHOOTING AND ELECTRICAL SYSTEM (GASOLINE VEHICLE) Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. Yellow Wire 2. 200 Ohm Setting Figure 19-18 Check Terminal Continuity – Model G425419 shown Using a multimeter set to 200 ohms, place the red (+) probe on the A1 terminal and the black (–) probe on the A2 terminal.
Page 286 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM (GASOLINE VEHICLE) Ensure that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. Disconnect the yellow wire from the DF terminal on the starter/generator. Cover the connector on the yellow wire to make sure the yellow wire will not short to ground.
Page 287 TROUBLESHOOTING AND ELECTRICAL SYSTEM (GASOLINE VEHICLE) Test Procedures WAVETEK 1000 2000 200k 200mA 1000 --- FUSED 750V 2427 Figure 19-20 Voltage Regulator Test TEST PROCEDURE 12 – Disconnected Kill Wire See General Warnings on page 1-2. NOTE: Keep the battery connected while performing this test procedure. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout cam in the MAINTENANCE position.
Page 288 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM (GASOLINE VEHICLE) 1. Ignition Gap Test Tool 2. Chassis 1. Disconnect White/Black Engine Kill Wire 2. Wire from Ignition Coil 2652 Figure 19-21 Ignition Spark Test Figure 19-22 White/Black Engine Kill Wire TEST PROCEDURE 13 – Ignition Spark See General Warnings on page 1-2.
Page 289 TROUBLESHOOTING AND ELECTRICAL SYSTEM (GASOLINE VEHICLE) Test Procedures TEST PROCEDURE 14 – Ignition Coil See General Warnings on page 1-2. The following test procedures will properly detect a coil that has failed in most cases; in rare cases however, some ignition coils can fail to operate at normal (warmer) operating temperatures.
Page 290 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM (GASOLINE VEHICLE) x100 1. x1K Ohm Setting 2648 Figure 19-24 Secondary Coil Resistance – In Vehicle Test Using an analog multimeter set to x1k ohms, measure the resistance of the secondary coil and spark plug cap together.
Page 291 TROUBLESHOOTING AND ELECTRICAL SYSTEM (GASOLINE VEHICLE) Test Procedures Figure 19-25 Ignition Coil and Cap Figure 19-26 Spark Plug Cap Removal 4.3. Using an analog multimeter set to x1k ohms, place the red (+) probe of the multimeter into the end of the spark plug cap that normally connects to the spark plug and place the black (–) probe into the end of the cap with the internal screw (Figure 19-27, Page 19-27).
Page 292 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM (GASOLINE VEHICLE) x100 x100 1. x1K Ohm Setting 2. Core 3. Spark Plug Cap 1. Ignition Coil Terminal 2. Core 3. x1K Ohm Setting 2649 2650 Figure 19-28 Primary Coil Resistance – Bench Test Figure 19-29 Secondary Coil and Cap Resistance –...
Page 293 TROUBLESHOOTING AND ELECTRICAL SYSTEM (GASOLINE VEHICLE) Test Procedures Disconnect wires from the (+M) and (–M) terminals of the key switch. Place the red (+) probe on the (+M) terminal and the black (–) probe on the (-M) terminal. With the key switch OFF, the reading should be continuity.
Page 294 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM (GASOLINE VEHICLE) should be no continuity. Press the lever and the reading should be continuity. If either reading is incorrect, replace the limit switch. See Reverse Buzzer Limit Switch Removal on page 20-20. TEST PROCEDURE 18 – Reverse Buzzer See General Warnings on page 1-2.
Page 295 TROUBLESHOOTING AND ELECTRICAL SYSTEM (GASOLINE VEHICLE) Test Procedures TEST PROCEDURE 21 – Neutral Lockout Cam See General Warnings on page 1-2. Check to be sure the lobes on the cam are pressing the neutral lockout limit switch lever as the Forward/Reverse handle is being shifted.
Page 296 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM (GASOLINE VEHICLE) WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 2691 Figure 19-31 Fuel Level Sending Unit Test The following resistance readings (in ohms) should be obtained depending on the position of the float inside the fuel tank.
Page 297 TROUBLESHOOTING AND ELECTRICAL SYSTEM (GASOLINE VEHICLE) Test Procedures Turn the key switch ON. The voltage reading should be the same as the battery voltage reading recorded earlier. If not, check the continuity of the blue and black wires (Figure 19-32, Page 19-33). The orange wire should remain disconnected for this step.
Page 299: Section 20 - Electrical Components (Gasoline Vehicle)
SECTION 20 – ELECTRICAL COMPONENTS (GASOLINE VEHICLE) DANGER • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. STARTER/GENERATOR TESTING THE STARTER/GENERATOR See Test Procedure 8 – Starter/Generator (Starter Function) on page 19-20 and Test Procedure 10 – Starter/Generator (Generator Function) on page 19-21.
Page 300: Disassembly Of The Starter/Generator To Service The Brushes
ELECTRICAL COMPONENTS (GASO- Starter/Generator LINE VEHICLE) Support the starter/generator so that when the pivot bolts are removed the starter/generator will not fall to the ground. Remove the two pivot nuts (7) and bolts (5) from the mounting bracket. Remove the starter/generator. DISASSEMBLY OF THE STARTER/GENERATOR TO SERVICE THE BRUSHES Remove brush covers (29 and 30).
Page 301: Brush Spring Inspection And Replacement
ELECTRICAL COMPONENTS (GASOLINE VEHICLE) Starter/Generator 1340 Figure 20-4 Inspect Brushes BRUSH SPRING INSPECTION AND REPLACEMENT Visually inspect springs. Replace all four springs if any spring is discolored from heat (straw or bluish in color). Install the four brushes (27) into their holders and insert the four brush springs (28) (Figure 20-3, Page 20-2). Insert the brush wiring terminal studs through the commutator end cover (23) and assemble using the terminal hardware (31).
Page 302: Starter/Generator Assembly
ELECTRICAL COMPONENTS (GASO- Starter/Generator LINE VEHICLE) STARTER/GENERATOR ASSEMBLY To prevent contact between the brushes and commutator as the commutator is installed, and possible damage to the brushes, pull back each brush spring and pull the brushes back from the center of the commutator end cover.
Page 303: Bearing Cleaning And Inspection
ELECTRICAL COMPONENTS (GASOLINE VEHICLE) Starter/Generator 1342 Figure 20-7 Output End Cover Assembly, Armature and Housing BEARING CLEANING AND INSPECTION Using a clean cloth, wipe the carbon dust from the two bearings. Inspect bearings by spinning them by hand and checking for both axial (A) and radial (B) play (Figure 20-8, Page 20-5). Replace the bearing if it is noisy, does not spin smoothly, or has excessive play.
Page 304: Bearing Removal
ELECTRICAL COMPONENTS (GASO- Starter/Generator LINE VEHICLE) BEARING REMOVAL Place the wedge attachment tool (P/N 1012812) between the bearing and the armature. Make sure the wedge attachment tool is supporting the inner race of the bearing. If a press is not available, secure a bearing puller (P/N 1012811) to the wedge attachment tool and pull the bearing off of the end of the armature shaft.
Page 305: Commutator Cleaning And Inspection
ELECTRICAL COMPONENTS (GASOLINE VEHICLE) Starter/Generator Figure 20-10 Field Coil Assembly COMMUTATOR CLEANING AND INSPECTION 1. Measure each position in two places, 90 degrees apart Figure 20-11 Inspect Commutator Clean the carbon dust, dirt and oil from the commutator. Visually inspect the commutator for worn, burned or glazed areas.
Page 306: Armature Ground Test
ELECTRICAL COMPONENTS (GASO- Starter/Generator LINE VEHICLE) CAUTION • Do not use emery cloth on the commutator. Particles of emery are conductive and may short-circuit the commutator bars. Do not use oil or lubricants on the commutator or brushes. Using a micrometer, measure the outside diameter at two points along the commutator. If the commutator outside diameter is less than 1.60 inches (40.6 mm), replace the armature and bearings (Figure 20-11, Page 20-7).
Page 307: Starter/Generator Rework
ELECTRICAL COMPONENTS (GASOLINE VEHICLE) Starter/Generator STARTER/GENERATOR REWORK Any rework must be performed by a qualified technician. Starter/generator service specifications are listed in the following table. ITEM SERVICE LIMIT Commutator diameter (minimum) 1.60 in. (41 mm) Concentric with armature shaft within 0.002 in.
Page 308: Starter/Generator Installation
ELECTRICAL COMPONENTS (GASO- Starter/Generator LINE VEHICLE) 9.2. Orient wire at A1 to be 1 inch (25.4 mm) away from A2 terminal as shown and tighten nut to 44 in·lb (5 N·m) (Figure 20-13, Page 20-10). See following NOTE. NOTE: Secure bottom nut of terminal with wrench before tightening top nut. 9.3.
Page 309: Belt Tension Adjustment
ELECTRICAL COMPONENTS (GASOLINE VEHICLE) Starter/Generator 1390 Figure 20-14 Starter/Generator Installation BELT TENSION ADJUSTMENT Belt tension should be checked periodically. If the belt slips when starter/generator motor operates, adjust belt to correct tension. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-3. Remove the access panel on the vehicle.
Page 310 ELECTRICAL COMPONENTS (GASO- Starter/Generator LINE VEHICLE) 1. Belt Tension Gauge 2. End View Figure 20-15 Belt Tension Gauge Page 20-12 2014 Precedent ® Golf Car Maintenance and Service Manual...
Page 311: Voltage Regulator
ELECTRICAL COMPONENTS (GASOLINE VEHICLE) Voltage Regulator VOLTAGE REGULATOR See General Warnings on page 1-2. TESTING THE VOLTAGE REGULATOR See Test Procedure 11 – Voltage Regulator on page 19-22. VOLTAGE REGULATOR REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-3. Disconnect the voltage regulator connector (3) from the wire harness (Figure 20-16, Page 20-13).
Page 312: Key Switch
ELECTRICAL COMPONENTS (GASO- Key Switch LINE VEHICLE) KEY SWITCH See General Warnings on page 1-2. TESTING THE KEY SWITCH See Test Procedure 15 – Key Switch (Engine Kill Circuit) on page 19-28. See also Test Procedure 4 – Key Switch (Starter Circuit) on page 19-16. KEY SWITCH REMOVAL Disconnect battery and spark plug wire(s).
Page 313: Key Switch Installation
ELECTRICAL COMPONENTS (GASOLINE VEHICLE) Solenoid KEY SWITCH INSTALLATION Reverse removal procedures to install key switch in the instrument panel. Connect wires to key switch. Install the instrument panel. 2.1. Connect the electrical connector (3) (Figure 20-17, Page 20-14). 2.2. Position the instrument panel (2) on the dash assembly. Make sure tabs on upper edge properly engage with the corresponding slots on the dash assembly.
Page 314: Fuse
ELECTRICAL COMPONENTS (GASO- Fuse LINE VEHICLE) FUSE See General Warnings on page 1-2. TESTING THE FUSE See Test Procedure 2 – Fuse on page 19-14. FUSE REMOVAL Disconnect battery. See Disconnecting the Battery – Gasoline Vehicles on page 1-3. Remove cover from fuse holder. Remove the fuse from the fuse holder.
Page 315: Kill Limit Switch
ELECTRICAL COMPONENTS (GASOLINE VEHICLE) Limit Switches KILL LIMIT SWITCH See General Warnings on page 1-2. Testing the Kill Limit Switch See Test Procedure 5 – Throttle Position Sensor (TPS) on page 19-17. The kill limit switch is housed inside the throttle position sensor. The throttle position sensor itself is not intended to be replaced.
Page 316: Neutral Lockout Cam
ELECTRICAL COMPONENTS (GASO- Neutral Lockout Cam LINE VEHICLE) Connect the black wire to common (COM) terminal, the green wire to the normally open (NO) terminal and the white wire to the normally closed (NC) terminal of the neutral lockout limit switch (Figure 20-19, Page 20-17). Connect battery and spark plug wire(s).
Page 317: Testing The Reverse Warning Buzzer
ELECTRICAL COMPONENTS (GASOLINE VEHICLE) Reverse Warning Buzzer TESTING THE REVERSE WARNING BUZZER See Test Procedure 18 – Reverse Buzzer on page 19-30. REVERSE WARNING BUZZER REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-3. Remove the instrument panel.
Page 318: Reverse Buzzer Limit Switch
ELECTRICAL COMPONENTS (GASO- Reverse Buzzer Limit Switch LINE VEHICLE) REVERSE BUZZER LIMIT SWITCH See General Warnings on page 1-2. TESTING THE REVERSE BUZZER LIMIT SWITCH See Test Procedure 17 – Reverse Buzzer Limit Switch on page 19-29. REVERSE BUZZER LIMIT SWITCH REMOVAL Disconnect battery and spark plug wire(s).
Page 319: Low Oil Warning Light
ELECTRICAL COMPONENTS (GASOLINE VEHICLE) Low Oil Warning Light LOW OIL WARNING LIGHT See General Warnings on page 1-2. TESTING THE LOW OIL WARNING LIGHT See Test Procedure 20 – Low Oil Warning Light on page 19-30. LOW OIL WARNING LIGHT REMOVAL Disconnect battery and spark plug wire(s).
Page 320: Fuel Gauge
ELECTRICAL COMPONENTS (GASO- Fuel Gauge LINE VEHICLE) FUEL GAUGE See General Warnings on page 1-2. With the key switch in the OFF position, the fuel gauge reads empty. When the key switch is turned to ON, the fuel gauge becomes active. TESTING THE FUEL GAUGE See Test Procedure 24 –...
Page 321: Fuel Level Sending Unit
ELECTRICAL COMPONENTS (GASOLINE VEHICLE) Fuel Level Sending Unit 4.2. Position the instrument panel (2) on the dash assembly. Make sure tabs on upper edge properly engage with the corresponding slots on the dash assembly. Ensure that there are no wires exposed or pinched during positioning.
Page 322: Ignition Coil
ELECTRICAL COMPONENTS (GASO- Ignition Coil LINE VEHICLE) BLACK 2438 Figure 20-24 Hour Meter Installation IGNITION COIL See General Warnings on page 1-2. TESTING THE IGNITION COIL See Test Procedure 13 – Ignition Spark on page 19-24 and Test Procedure 14 – Ignition Coil on page 19-25. IGNITION COIL REMOVAL Disconnect battery and spark plug wire(s).
Page 323: Ignition Coil Installation
ELECTRICAL COMPONENTS (GASOLINE VEHICLE) Ignition Coil Figure 20-25 Stiffener Removal Figure 20-26 Fan Housing Removal Figure 20-27 Ignition Coil Removal IGNITION COIL INSTALLATION NOTE: If a new ignition coil is being installed, the spark plug cap, gasket, protector tube and grommet must be removed from the old coil and installed on the new coil.
Page 324 ELECTRICAL COMPONENTS (GASO- Ignition Coil LINE VEHICLE) 0.012 Inch (0.304 mm) Figure 20-28 Clean Grommet Figure 20-29 Mount Ignition Coil Using Feeler Gauge Remove the gasket (1) and protector tube (3) from the old coil. See following NOTE. NOTE: Moisten the spark plug wire with water to make gasket removal and installation easier. Remove the grommet (4) from the old spark plug wire.
Page 325: Oil Level Sensor
ELECTRICAL COMPONENTS (GASOLINE VEHICLE) Oil Level Sensor CAUTION • Make sure wire harness is routed and secured away from the muffler. 18. Install the muffler. See Muffler Installation on page 23-1. 19. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 1, Page 1-4. OIL LEVEL SENSOR See General Warnings on page 1-2.
Page 326: General Information
Club Car recommends a group 70, side-post battery (P/N 1012328), with a 650 cranking amp rating at 32 °F (0 °C) (500 CCA at 0 °F (-17.8 °C)) and a reserve capacity of at least 105 minutes. The group 70 classification indicates battery size: 8-1/4 inches W x 6-1/2 inches D x 7-1/4 inches H (21.0 cm W x 16.5 cm D x 18.4 cm H).
Page 327: Preventive Maintenance
ELECTRICAL COMPONENTS (GASOLINE VEHICLE) Battery Any corrosion around the positive (+) or negative (–) terminals should be washed off with a solution of baking soda and water (1 cup (237 mL) per 1 gallon (3.8 L) of water). Rinse solution off the battery. Do not allow this solution to enter battery.
Page 328: Self-Discharge
ELECTRICAL COMPONENTS (GASO- Battery LINE VEHICLE) SELF-DISCHARGE Dirt and battery acid can provide a path for a small current draw that slowly discharges the battery. To minimize self-discharge, the battery should always be kept clean. Hot weather also has an effect on a battery’s self-discharge rate. The higher the temperature, the quicker a battery will discharge.
Page 329: Battery Removal
ELECTRICAL COMPONENTS (GASOLINE VEHICLE) Battery IMPURITY ALLOWABLE CONTENT (PARTS PER MILLION) Suspended matter Trace Total solids 100.0 Calcium and Magnesium Oxides 40.0 Iron Ammonia Organic matter 50.0 Nitrates 10.0 Nitrites Chloride BATTERY REMOVAL See General Warnings on page 1-2. See also DANGER on page 20-27. Disconnect battery.
Page 330: Battery Installation
ELECTRICAL COMPONENTS (GASO- Ground Cables LINE VEHICLE) BATTERY INSTALLATION See General Warnings on page 1-2. See also DANGER on page 20-27. Place the battery into the vehicle. Make sure the battery posts are facing the engine. Secure the battery to the vehicle with the clamp. Install two screws and tighten to 31 in·lb (3.5 N·m). Connect battery.
Page 331: Testing The Ground Cables
ELECTRICAL COMPONENTS (GASOLINE VEHICLE) Ground Cables TESTING THE GROUND CABLES See Test Procedure 3 – Ground Cables on page 19-15. 2014 Precedent ® Golf Car Maintenance and Service Manual Page 20-33...
Page 333: Section 21 - As26 Fe 350 Engine
SECTION 21 – AS26 FE 350 ENGINE DANGER • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION See General Warnings on page 1-2. This vehicle is powered by a 4-cycle, overhead valve, single cylinder, air-cooled engine. The S26 engine is identified by labelling on the blower housing and has mechanical lifters as opposed to a hydraulically-lifted valve train.
Page 334: Spark Plug
General Information AS26 FE 350 ENGINE SPARK PLUG Spark plugs are selected to suit specific engine design and vehicle operating conditions. The spark plug (P/N AM1232301) is designed to give maximum life and efficient combustion of fuel. The spark gap should be set between 0.027 to 0.031 inch (0.69 to 0.79 mm).
Page 335: Cylinder Head
AS26 FE 350 ENGINE Cylinder Head Spark Plug Installation NOTE: Before installing the plug, check the condition of the threads in the cylinder head. Soften deposits in cylinder head threads with penetrating oil and clean the threads with a tap if necessary. Use a high temperature, anti-seize lubricant on the threads of the spark plug to reduce friction when installing a new plug, and reduce “gauling”...
Page 336: Crankcase
Crankcase AS26 FE 350 ENGINE 1302 1304 Figure 21-2 Measure Valve Clearance Figure 21-3 Valve Clearance CRANKCASE See General Warnings on page 1-2. ENGINE REMOVAL To perform repairs on crankcase components, remove engine from the vehicle. See following CAUTION. CAUTION •...
Page 337: Crankcase Cover Removal
AS26 FE 350 ENGINE Crankcase Remove crankcase oil drain plug and filler tube. Tip the engine slightly to allow all of the oil to drain from the crankcase. Dispose of engine oil properly. CRANKCASE COVER REMOVAL Remove yellow jumper wire (11) from cord connector (12) (Figure 21-4, Page 21-5). Remove nuts and clamps at two-ended bolts (1 and 2) (Figure 21-5, Page 21-5).
Page 338: Oil Level Sensor
Crankcase AS26 FE 350 ENGINE Figure 21-6 Engine Mounting Plate OIL LEVEL SENSOR Testing the Oil Level Sensor See See Oil Level Sensor on page 19-30. Oil Level Sensor Removal If not already removed, remove crankcase cover. See Crankcase Cover Removal on page 21-5. Disconnect the oil level sensor wire (2) from the cord connection (1) (Figure 21-7, Page 21-7).
Page 339: Crankcase Cover Installation
AS26 FE 350 ENGINE Crankcase Position the sensor and bracket on inside of crankcase and install two mounting screws. Connect sensor wire (2) to cord connector (1). Install screw (3) through wire clamp and into crankcase cover. Tighten to 30 in·lb (3.4 N·m). Figure 21-7 Oil Level Sensor CRANKCASE COVER INSTALLATION CAUTION...
Page 340: Ignition Coil And Flywheel
Ignition Coil and Flywheel AS26 FE 350 ENGINE Figure 21-8 Crankcase Cover Installation IGNITION COIL AND FLYWHEEL See General Warnings on page 1-2. IGNITION COIL AND FLYWHEEL REMOVAL Loosen three screws (2) and remove the remaining four screws (1) attaching the flywheel housing as shown, then remove the housing (Figure 21-9, Page 21-8).
Page 341: Flywheel Installation
AS26 FE 350 ENGINE Ignition Coil and Flywheel CAUTION • The flywheel nut has right-hand threads. Turn it clockwise to tighten, or counterclockwise to loosen. • Do not damage the fan blades with the strap wrench. Do not place screwdriver or pry bar in the fan blades.
Page 342: Ignition Coil Installation
Engine Installation AS26 FE 350 ENGINE Figure 21-13 Fan and Flywheel Installation IGNITION COIL INSTALLATION Installation is the reverse of removal. While tightening the two bolts (6), use a bronze feeler gauge to adjust the ignition coil air gap to 0.012 inch (0.304 mm) (Figure 21-12, Page 21-9).
Page 343 AS26 FE 350 ENGINE Engine Installation 9.2. Reinsert dip stick until fully seated. 9.3. Oil must be in the SAFE LEVEL range. CAUTION • Do not overfill with oil. 1.Full level 2. Safe level 3. Low level. Figure 21-14 Check Engine Oil Level 10.
Page 344: Torque Specifications
Torque Specifications AS26 FE 350 ENGINE TORQUE SPECIFICATIONS ITEM SIZE LIMITS Cylinder head bolts 220 in·lb (24 N·m) Valve clearance adjustment nuts 90 in·lb (10 N·m) Connecting rod bolts 180 in·lb (20 N·m) (coat threads with engine oil) Flywheel retaining nut 100 ft·lb (135 N·m) Crankcase cover to block bolts 22 ft·lb (31 N·m)
Page 345: Section 22 - Fuel System
SECTION 22 – FUEL SYSTEM DANGER • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION The engine is equipped with a float bowl type carburetor with fixed jets that require no adjustment. The carburetor atomizes the fuel, mixes it with air, and feeds the combustible mixture into the cylinder.
Page 346 Carburetor FUEL SYSTEM 2698 Figure 22-1 Carburetor Mounting Page 22-2 2014 Precedent ® Golf Car Maintenance and Service Manual...
Page 347: Main Jet Elevation/Size Chart
FUEL SYSTEM Carburetor MAIN JET ELEVATION/SIZE CHART JET SIZE KAWASAKI FE350 CARBURETOR ENGINE 0 TO 3300 FT. 3300 TO 9900 FT. 9900 FT. AND HIGHER NUMBER MODEL/REVISION (0 TO 1000 M) (1000 TO 3000 M) (3000 M AND HIGHER) 32282 AS02, BS02 AS03, CS03, DS03 32337...
Page 348 Carburetor FUEL SYSTEM Figure 22-2 Drain Bowl Figure 22-3 Mark Carburetor and Bowl for Alignment Remove the carburetor fuel bowl retaining screw and washer (12), then remove the fuel bowl (10) and clean it with a nonflammable solvent (Figure 22-4, Page 22-4). See following NOTE. NOTE: Make sure the fuel bowl gasket (9) remains properly seated in the carburetor body when the fuel bowl is removed.
Page 349 FUEL SYSTEM Carburetor Select the proper size main jet. See Main Jet Elevation/Size Chart on page 22-3. Check the size designation on the jet to make sure it is the correct part. Install the new main jet and tighten it to 12 in·lb (1.4 N·m). See following CAUTION and NOTE. CAUTION •...
Page 350: Engine Control Linkage
Engine Control Linkage FUEL SYSTEM 15. Install carburetor vent line (14) and clamp (13). 16. Install the governor cable (30). 17. Install the governor guard (5), flat washer and nylon lock nut. Tighten to 30 in·lb (3.4 N·m). 18. Install the intake hose (23) and secure with hose clamp. NOTE: Make sure the intake hose is not twisted during installation.
Page 351 FUEL SYSTEM Engine Control Linkage With the governor lever arm loose on the governor shaft, use a 1/8-inch (3.2 mm) punch or scratch awl to turn the governor arm shaft counterclockwise until it stops. Then pull the governor lever arm rearward until the carburetor throttle is in the “wide open throttle”...
Page 352: Accelerator Cable
Engine Control Linkage FUEL SYSTEM ACCELERATOR CABLE Accelerator Cable Removal Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-3. Access the pedal group and remove accelerator cable from the pedal group. See Pedal Group Removal on page 5-4.
Page 353: Engine Rpm Adjustment
FUEL SYSTEM Engine Control Linkage ENGINE RPM ADJUSTMENT DANGER • Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison. If the governor is adjusted, proceed to step 2; otherwise, adjust the governor. See Governor Cable Installation and Adjustment on page 22-6.
Page 354: Choke And Air Intake System
Choke and Air Intake System FUEL SYSTEM Check the engine RPM setting to ensure that it has not been altered. See Engine RPM Adjustment on page 22-9. CHOKE AND AIR INTAKE SYSTEM See General Warnings on page 1-2. GENERAL INFORMATION The choke and air intake system is a simple mechanism requiring very little or no maintenance.
Page 355: Choke Button
FUEL SYSTEM Choke and Air Intake System 2678 Figure 22-9 Air Intake Mounting CHOKE BUTTON The choke button actuates the choke mechanism via a rod that connects to the button and the choke (Figure 22-8, Page 22-10). Pressing in the button actuates the choke. A spring clip attaches the rod to the choke. If the choke button requires service, the kick plate must be removed.
Page 356: Air Intake Components Removal
Choke and Air Intake System FUEL SYSTEM AIR INTAKE COMPONENTS REMOVAL Turn the key switch to the OFF position and remove the key, place the Forward/Reverse handle in the NEUTRAL position, and chock the wheels. Access the engine compartment. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-3. Hose (3) may be removed by removing the clamps (4) at the choke and the carburetor (Figure 22-9, Page 22-11).
Page 357 • If air filter housing is extremely dirty, clean thoroughly. • Use only Club Car replacement air filters (P/N 102558201) or equivalent. The use of other air filters could result in engine damage. If the air filter is too small, the cover will seat before the filter can seal, leaving space for dirt to pass into the engine on all sides of the element.
Page 358: Fuel Filter
Fuel Filter FUEL SYSTEM FUEL FILTER See General Warnings on page 1-2. GENERAL INFORMATION Fuel is supplied to the fuel pump and carburetor through flexible lines. An in-line filter is installed between the fuel tank and the fuel pump (Figure 22-11, Page 22-15). The filter, fuel lines, and the fuel tank vent should be inspected periodically for leaks.
Page 359 FUEL SYSTEM Fuel Filter TO CRANKCASE 2699 Figure 22-11 Fuel and Vent Lines 2014 Precedent ® Golf Car Maintenance and Service Manual Page 22-15...
Page 360: Fuel Pump
MARK 4 DAYPERM C-U-06-030 or AVON GREENBAR G-05-018 fuel hose (CC P/N 102865101). To remain in compliance with California regulations, replace any fuel hose on this vehicle with Club Car P/N 102865101 having ‘DAYPERM C-U-06-030’ or ‘AVON GREENBAR G-05-018’ printed on the hose, or equivalent.
Page 361: Fuel Tank
FUEL SYSTEM Fuel Tank Connect battery. See Connecting the Battery – Gasoline Vehicles, Section 1, Page 1-4. Turn the fuel shut-off valve to the open position (Figure 22-13, Page 22-21). Place the Forward/Reverse handle in the NEUTRAL position, chock the wheels, and the neutral lockout cam in the MAINTENANCE position.
Page 362: Fuel Tank Disposal
Fuel Tank FUEL SYSTEM DANGER • Gasoline – Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and service area. Service only in a well-ventilated area. WARNING • Do not attempt to siphon fuel using a hose that does not have a built-in suction device. •...
Page 363: Fuel Tank Storage
FUEL SYSTEM Fuel Tank CAUTION • Dispose of wastewater and fuel tank in accordance with local, state, and federal laws and ordinances. FUEL TANK STORAGE Remove the cap from the tank and thoroughly rinse it with water. In a well-ventilated area, flush the fuel tank with water to remove any remaining fuel. In a well-ventilated area, set the tank upside down so that the water can drain out of it.
Page 364: Fuel Lines
Fuel Lines FUEL SYSTEM 11. Allow the engine to run for a few minutes to ensure that the fuel lines are full of fuel. 12. Inspect each fuel line for leaks. 12.1.Check all of the fuel line clamps at the carburetor, fuel filter, fuel pump, and fuel tank for leaks. 12.2.Inspect each fuel line to ensure that the lines are not cracked, cut, or worn.
Page 365: Fully Open Position
CARBON CANISTER WARNING • If the carbon canister is damaged, only use an OEM (Club Car) replacement that is specifically designed and approved for use on this vehicle. Do not attempt to repair it. See the following canister removal procedure.
Page 366: Carbon Canister Installation
Carbon Canister FUEL SYSTEM Detail A: Side View 1. Clamp 2. Vent Tube (Fuel Tank to Canister) 3. Vent Tube (Canister to Engine) 4. Vent Tube (Canister to Atmosphere) 5. Carbon Canister 6. Mounting Bracket 2447 Figure 22-14 Carbon Canister, Hoses and Routing CARBON CANISTER INSTALLATION Align canister mounting tabs with slots in mounting bracket (6) and push canister (5) into bracket (Figure 22-14, Page 22-22).
Page 367: Section 23 - Exhaust System
SECTION 23 – EXHAUST SYSTEM DANGER • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. MUFFLER MUFFLER REMOVAL WARNING • Hot! Do not attempt to service hot engine or exhaust system. Failure to heed this warning could result in severe burns.
Page 368 Muffler EXHAUST SYSTEM Place the Forward/Reverse handle in the NEUTRAL position, chock the wheels, and the neutral lockout cam in the MAINTENANCE position (Figure 24-1, Page 24-2). 10. Start the engine and check for exhaust leaks and proper engine operation. See following DANGER. DANGER •...
Page 369: Section 24 - Unitized Transaxle (Gasoline Vehicle)
SECTION 24 – UNITIZED TRANSAXLE (GASOLINE VEHICLE) DANGER • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION The vehicles addressed in this manual are equipped with heavy-duty, fully-synchronized Unitized Transaxles manufactured by either Kawasaki or Graziano. The unitized transaxle utilizes fully-synchronized internal gearing to change vehicle direction.
Page 370: Governor System
General Information UNITIZED TRANSAXLE (GASOLINE VEHICLE) WARNING • With the cam in the MAINTENANCE position and the engine running, the vehicle may move suddenly if the Forward/Reverse handle is shifted or accidentally bumped. To prevent this, chock the front and rear wheels and firmly set the park brake before servicing or leaving the vehicle.
Page 371: Tools Required For This Section
UNITIZED TRANSAXLE (GASOLINE VEHICLE) General Information C l u b C a r Figure 24-3 Shifter Positions (Top View) Figure 24-4 Lubricant Level (should be level with bottom of hole) and Drain Plug TOOLS REQUIRED FOR THIS SECTION Hydraulic floor jack (or chain hoist) 12 to 18 in.
Page 372: Axle Bearing And Shaft - Kawasaki
Axle Bearing and Shaft – Kawasaki UNITIZED TRANSAXLE (GASOLINE VEHICLE) AXLE BEARING AND SHAFT – KAWASAKI See General Warnings on page 1-2. Removal of the unitized transaxle is not required for servicing or replacing axle shafts, axle bearings, or axle shaft oil seals.
Page 373: Axle Bearing
UNITIZED TRANSAXLE (GASOLINE VEHICLE) Axle Bearing and Shaft – Kawasaki Figure 24-6 Rolling Head Prybar Figure 24-7 Seal Lip Inspect the axle shaft assembly to be sure the bearing (71) and collar (73) have not slipped and are still seated against the shoulder on the axle shaft (Figure 24-8, Page 24-6).
Page 374 Axle Bearing and Shaft – Kawasaki UNITIZED TRANSAXLE (GASOLINE VEHICLE) Figure 24-8 Differential Gear Case and Axle Tubes Axle Bearing Installation Ensure that the retaining ring (70) is loosely placed on the axle shaft. See preceding NOTE. Install a new axle bearing (71) on axle (67 or 68). Push bearing onto axle until bearing is flush against axle shoulder (Figure 24-8, Page 24-6).
Page 375: Axle Shaft And Oil Seal Installation
UNITIZED TRANSAXLE (GASOLINE VEHICLE) Axle Bearing and Shaft – Kawasaki Place a new sealed bearing (71) on shaft (67 or 68) (Figure 24-8, Page 24-6). Install collar (73) onto axle shaft. Place axle assembly on bearing puller wedge attachment and press collar onto axle.
Page 376: Axle Bearing And Shaft - Graziano
Axle Bearing and Shaft – Graziano UNITIZED TRANSAXLE (GASOLINE VEHICLE) Figure 24-9 Press Bearing and Collar From Shaft Using Figure 24-10 Axle Seal and Seal Tool Bearing Puller Wedge Attachment AXLE BEARING AND SHAFT – GRAZIANO See General Warnings on page 1-2. AXLE SHAFT AND OIL SEAL REMOVAL Disconnect the batteries and discharge the controller.
Page 377: Axle Bearing
UNITIZED TRANSAXLE (GASOLINE VEHICLE) Axle Bearing and Shaft – Graziano 6.2. Use a press to separate the axle oil seal (15) from the adapter ring (39) (Figure 24-13, Page 24-9). Retain the adapter ring and discard the oil seal. 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.
Page 378: Unitized Transaxle Removal
Unitized Transaxle Removal UNITIZED TRANSAXLE (GASOLINE VEHICLE) 1.2. Place a new seal (15) in the adapter ring with the seal lip facing toward the adapter ring lip (Figure 24-13, Page 24-9). Use an axle seal tool (P/N 1014162) and mallet to tap it in until it seats firmly in position. A hydraulic press may also be used with the axle seal tool.
Page 379 UNITIZED TRANSAXLE (GASOLINE VEHICLE) Unitized Transaxle Removal Figure 24-15 Carburetor Vent Tube Figure 24-16 Air Intake Hose 4.3. Disconnect impulse line from fuel pump (Figure 24-17, Page 24-11). 4.4. Loosen the hose clamp and then disconnect the fuel line from the carburetor. To prevent spilling fuel, the disconnected end of the line can be plugged with a 1/4-inch bolt (Figure 24-18, Page 24-11).
Page 380 Unitized Transaxle Removal UNITIZED TRANSAXLE (GASOLINE VEHICLE) 2398 Figure 24-19 Throttle Cable Mounting Figure 24-20 Engine Ground Wire 4.7. Use a screwdriver or flat blade to snap the shifter cable rod end (1) from the shifter arm (2) on the unitized transaxle.
Page 381 UNITIZED TRANSAXLE (GASOLINE VEHICLE) Unitized Transaxle Removal Figure 24-23 Oil Level Sensor Jumper Wire Figure 24-24 Ignition Kill Wire Disconnect the brake cables. Remove bow tie locking pins (1) and brake cable clevis pins (2) and using tool (P/N 1025555) compress tangs on cable end and remove cable from bracket (4) (Figure 24-25, Page 24-13). Figure 24-25 Brake Cable (Rear View) Remove the lower shock mounting hardware from both rear shocks (Figure 24-26, Page 24-14).
Page 382 Unitized Transaxle Removal UNITIZED TRANSAXLE (GASOLINE VEHICLE) Position floor jack under hitch bracket or frame. 2400 Figure 24-26 Shock Absorbers Figure 24-27 Floor Jack Positioned Under Vehicle Raise vehicle just enough to relieve tension from leaf springs, then remove the bolts securing the leaf springs to the shackles (Figure 24-28, Page 24-14).
Page 383 UNITIZED TRANSAXLE (GASOLINE VEHICLE) Unitized Transaxle Removal 2402 2403 Figure 24-30 Raise Vehicle Figure 24-31 Position Jack Stands On Both Sides of Frame 12. Pull the floor jack from beneath the vehicle and move it away. 13. Carefully lift the snubber (1) out of the snubber bracket (2) in the vehicle frame and lower it to the floor (Figure 24-32, Page 24-15).
Page 384 Unitized Transaxle Removal UNITIZED TRANSAXLE (GASOLINE VEHICLE) NOTE: Place the blocks so they will support the engine when the transaxle is detached and moved away from the engine. 16. Remove the drive belt. 16.1.Grasp belt midway between drive and driven clutch and pull up on belt to force the driven clutch sheaves apart.
Page 385 UNITIZED TRANSAXLE (GASOLINE VEHICLE) Unitized Transaxle Removal 2406 2407 Figure 24-38 Governor Cable Bracket Figure 24-39 Accelerator Cable Bracket 21. Remove the six bolts mounting the unitized transaxle to the engine. 21.1.Remove four transaxle mounting bolts and flat washers (one at each corner of the transaxle mounting plate) (Figure 24-40, Page 24-17).
Page 386: Unitized Transaxle Installation
Unitized Transaxle Installation UNITIZED TRANSAXLE (GASOLINE VEHICLE) UNITIZED TRANSAXLE INSTALLATION See General Warnings on page 1-2. Install the wheels. See Wheel Installation, Section 8, Page 8-1. Install the leaf springs. See Rear Suspension on page 9-1. Position the transaxle mounting plate on the two mounting studs at the rear of the engine, and then install the two mounting nuts finger tight (Figure 24-41, Page 24-18).
Page 387 UNITIZED TRANSAXLE (GASOLINE VEHICLE) Unitized Transaxle Installation Figure 24-43 Driven Clutch and Key Figure 24-44 Snubber and Bracket 13. Position the floor jack under the rear frame crossmember and raise the jack high enough to support the vehicle (Figure 24-45, Page 24-19). Make sure the vehicle is stable on the jack, then remove the jack stands. 14.
Page 388 Unitized Transaxle Installation UNITIZED TRANSAXLE (GASOLINE VEHICLE) 17. Connect brake cables. See Brake Cable Installation on page 6-14. 18. Route the engine kill switch wire (18-gauge white/black) through the same retainers that hold the accelerator cable. Connect the wire to the bullet connector at the lower right front of the engine (Figure 24-48, Page 24-20). Figure 24-47 Shock Absorber Figure 24-48 Ignition Kill Wire 19.
Page 389 UNITIZED TRANSAXLE (GASOLINE VEHICLE) Unitized Transaxle Installation 2399 Figure 24-51 Connect Shifter Cable Figure 24-52 Engine Ground Wire 23. Insert the accelerator cable through the hole in the frame and connect the accelerator cable to the pedal group as described in Pedal Group – Gasoline Vehicle on page 5-4. Position the accelerator cable in the mounting brackets in the vehicle base and adjust mounting nuts (1) to remove all slack in the wire portion of the cable.
Page 390 Unitized Transaxle Installation UNITIZED TRANSAXLE (GASOLINE VEHICLE) 2644 Figure 24-55 Impulse Line Figure 24-56 Air Intake Hose 27. Connect carburetor vent tube to carburetor and secure with hose clamp (Figure 24-57, Page 24-22). Figure 24-57 Carburetor Vent Tube 28. Install transaxle drain plug and tighten to 21 ft·lb (28.5 N·m). 29.
Page 391: Forward/Reverse Shifter Cable
UNITIZED TRANSAXLE (GASOLINE VEHICLE) Forward/Reverse Shifter Cable DANGER • Repair all fuel leaks before operating the vehicle. 34. Start the engine and check for fuel leaks. If the fuel pump leaks, a rebuild kit must be installed to replace all gaskets and diaphragms.
Page 392 Forward/Reverse Shifter Cable UNITIZED TRANSAXLE (GASOLINE VEHICLE) 2408 Figure 24-58 Forward/Reverse Shifter Cable Page 24-24 2014 Precedent ® Golf Car Maintenance and Service Manual...
Page 393: Forward/Reverse Shifter Cable Adjustment
UNITIZED TRANSAXLE (GASOLINE VEHICLE) Forward/Reverse Shifter Cable FORWARD/REVERSE SHIFTER CABLE ADJUSTMENT With the shifter lever of the unitized transaxle in the NEUTRAL position (Figure 24-58, Page 24-24), the Forward/Reverse handle (20) should be straight up. For minor adjustments, the lock nut (26) may be loosened and the ball joint socket (27) rotated to get the proper adjustment.
Page 395: Section 25 - Torque Converter (Gasoline Vehicle)
SECTION 25 – TORQUE CONVERTER (GASOLINE VEHICLE) DANGER • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. GENERAL INFORMATION The torque converter consists of a drive clutch, a driven clutch, and a drive belt. The drive clutch, which is mounted to the engine, is in the open position when the engine is at idle.
Page 396: Troubleshooting
Troubleshooting TORQUE CONVERTER (GASOLINE VEHICLE) TROUBLESHOOTING See General Warnings on page 1-2. Maintaining proper adjustment of the engine and governor, as well as the torque converter, is essential to the troubleshooting process. If these adjustments are within specifications and, when climbing a steep hill, the engine begins to lose RPM before the drive belt reaches the top of the driven clutch, there is a torque converter problem.
Page 397: Drive Belt
TORQUE CONVERTER (GASOLINE VEHICLE) Drive Belt DRIVE BELT See General Warnings on page 1-2. The drive belt should be inspected semiannually for wear and (or) glazing. If it is excessively worn, frayed, or glazed, replace the belt. As the drive belt wears, the engine RPM will increase to compensate for the change in torque converter ratio. This will keep the vehicle’s maximum ground speed correct.
Page 398: Drive Clutch
Drive Clutch TORQUE CONVERTER (GASOLINE VEHICLE) DRIVE CLUTCH See General Warnings on page 1-2. CAUTION • Be very careful when handling the clutches. A clutch that has been dropped will not be properly balanced. If either clutch is dropped, assume that it is damaged and replace it. DRIVE CLUTCH REMOVAL Remove the drive belt as instructed.
Page 399 TORQUE CONVERTER (GASOLINE VEHICLE) Drive Clutch 2700 Figure 25-5 Shock Absorbers Figure 25-6 Rear Shackle Raise the rear of the vehicle enough to allow the centerline of the drive clutch to drop below the frame rails for access to the bolt securing the drive clutch. Place jack stands beneath the frame rails just forward of the spring mounts.
Page 400: Drive Clutch Cleaning And Inspection
Drive Clutch TORQUE CONVERTER (GASOLINE VEHICLE) CAUTION • Do not hit or tap the clutch with a hammer. Do not pry the clutch. These actions will damage the clutch. DRIVE CLUTCH CLEANING AND INSPECTION Use a dry, lint-free cloth to clean clutch parts. CAUTION •...
Page 401 TORQUE CONVERTER (GASOLINE VEHICLE) Drive Clutch Figure 25-7 Drive Clutch Assembly 2014 Precedent ® Golf Car Maintenance and Service Manual Page 25-7...
Page 402: Drive Clutch Disassembly
Drive Clutch TORQUE CONVERTER (GASOLINE VEHICLE) DRIVE CLUTCH DISASSEMBLY CAUTION • The drive clutch is balanced as an assembly. Before disassembly, make match marks on the drive clutch hub and on the moveable face assembly so they can be reassembled in the same positions (Figure 25-8, Page 25-8).
Page 403 TORQUE CONVERTER (GASOLINE VEHICLE) Drive Clutch Figure 25-10 Drive Button Mounting Figure 25-11 Weight Position Remove the clutch weights: 5.1. Remove the screws (1) and flat washers (2) attaching the weights (3) as shown (Figure 25-11, Page 25-9). 5.2. Pull the weight assemblies (3), with pins, from slots (4) in the clutch. See following NOTE. NOTE: Before removing, note the orientation of the wave washer (1) and secondary weight (2) on the primary weight (3) (Figure 25-12, Page 25-9).
Page 404: Inspection Of Drive Clutch Parts
Drive Clutch TORQUE CONVERTER (GASOLINE VEHICLE) Remove the retaining ring (3) from the shaft of the fixed face assembly (7) and slide the moveable face (14) off the shaft (Figure 25-7, Page 25-7). See following NOTE. NOTE: If the moveable face is removed from the hub of the fixed face, the spiral back-up rings (12) must be replaced with new ones (Figure 25-7, Page 25-7).
Page 405: Drive Clutch Assembly
TORQUE CONVERTER (GASOLINE VEHICLE) Drive Clutch DRIVE CLUTCH ASSEMBLY Press idler bearing (6) onto the shaft of the fixed face assembly (7). Press on the inner race of the bearing only. Make sure that the cup side of bearing is facing away from the fixed face (Figure 25-7, Page 25-7). Using needle nose pliers, install the spring retainer (5) onto the spring (4).
Page 406: Drive Clutch Installation
Drive Clutch TORQUE CONVERTER (GASOLINE VEHICLE) 14. Compress each take-up spring and install the drive button over the rib and take-up spring (Figure 25-10, Page 25-9). 15. Install a no. 10-24 button retaining screw with flat washer through each button and into the rib. Tighten the screws to 34 in·lb (3.8 N·m) (Figure 25-11, Page 25-9).
Page 407: Driven Clutch
TORQUE CONVERTER (GASOLINE VEHICLE) Driven Clutch 2701 Figure 25-17 Leaf Spring and Shackles Figure 25-18 Shock Absorbers Lower vehicle and remove the lifting device. Install the drive belt as instructed. See Drive Belt Installation on page 25-3. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles on page 1-4. Drive the vehicle and check for proper operation.
Page 408: Driven Clutch Disassembly
Driven Clutch TORQUE CONVERTER (GASOLINE VEHICLE) DRIVEN CLUTCH DISASSEMBLY Using external snap ring pliers, remove the retaining ring (4) (Figure 25-19, Page 25-14). See following WARNING. WARNING • Do not place fingers under the cam when removing the cam. The moveable face may spin when the cam buttons release from the cam ramps, resulting in severe personal injury.
Page 409: Driven Clutch Assembly
TORQUE CONVERTER (GASOLINE VEHICLE) Driven Clutch DRIVEN CLUTCH ASSEMBLY Place the three drive buttons (6) in position. Apply one drop of Loctite ® 222 to each of the socket-head cap screws and then install and tighten them to 8 in·lb (0.9 N·m) (Figure 25-21, Page 25-15). Slide the moveable face assembly (7) onto the fixed face shaft (8).
Page 410 Driven Clutch TORQUE CONVERTER (GASOLINE VEHICLE) Holding the cam (4) in position for assembly on the shaft, install the other end of the spring (5) into the center spring hole of the cam. Rotate the cam until the keyway is aligned with the key (3) on the fixed face assembly, and then start the cam onto the shaft approximately 1/4 to 3/8 inch (6.3 to 9.5 mm).
Page 411: Driven Clutch Installation
TORQUE CONVERTER (GASOLINE VEHICLE) Driven Clutch 5.2.4. Hold the clutch assembly and cam installation tool together and place the fixed face down on spaced blocks (Figure 25-22, Page 25-16). 5.2.5. Place the cam press hub (6) onto the cam installation bolt and thread it down onto the cam hub, centering the press hub onto the cam hub.
Page 413: Section 26 - Iq Display Module (Iqdm) And Iqdm-Pdiagnostics: Excel System With Eric Charging
SECTION 26 – IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH ERIC CHARGING DANGER • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. NOTE: For information specific to the IQDM-P handset programming features, see IQ Display Module Programmer (IQDM-P): Excel System with ERIC Charging on page 27-1.
Page 414: Quick Reference Guide - Excel With Eric Charging System
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH Quick Reference Guide – Excel with ERIC Charging System ERIC CHARGING QUICK REFERENCE GUIDE – EXCEL WITH ERIC CHARGING SYSTEM OPERATION: Change screen contrast for better viewing by selecting the following: Programmer Setup, Program, LCD Contrast Preset Favorites: Select a frequently viewed screen, push and hold one of the three yellow keys until the display reads, “1,2,3 Bookmark Set”.
Page 415: Introductory Display
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH ERIC CHARGING Introductory Display INTRODUCTORY DISPLAY Immediately after the handset is connected to the vehicle, it begins loading the vehicle speed controller information. After a few seconds, the screen displays the following menu items: •...
Page 416: Menu Navigation
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH Menu Navigation ERIC CHARGING MENU NAVIGATION The NAVIGATION BUTTON (1) is the four-arrow button located on the left side of the handset (Figure 26-3, Page 26-3). This button is used to navigate through and select menus. Pressing the up or down arrows allows the user to scroll through the menu items.
Page 417: Information
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH ERIC CHARGING Monitor Menu INFORMATION The information menu displays the model number, serial number, manufacturer date and software version of the speed controller. See Information on page 26-20. PROGRAMMER SETUP The programmer setup menu allows the user to set the LCD contrast, display the fault history of the programmer as well as various other information pertaining to the handset such as model number, serial number, OEM information, etc.
Page 418: Speed
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH Monitor Menu ERIC CHARGING SPEED Vehicle speed in mph. Only visible with the IQDM-P. THROTTLE Indicates the position of the accelerator pedal from 0% (pedal not pressed) between 95 and 100% (pedal fully pressed). This item can be monitored when the key switch is in the ON or OFF position.
Page 419: Foot Input
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH ERIC CHARGING Monitor Menu FOOT INPUT Indicates the status of the MCOR (Motor Controller Output Regulator) internal limit switch: on or off. When the accelerator pedal is unpressed, the handset should indicate that the limit switch is off. When the accelerator pedal is pressed and the key switch is in the ON position, the display should indicate that the limit switch is on.
Page 420: Password Tries (Iqdm-P Only)
“private speed mode”. In the event that “private speed mode” is locked out, the controller must be removed and shipped to Club Car before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 27-5.
Page 421: Faults Menu
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH ERIC CHARGING Faults Menu FAULTS MENU CAUTION • A failed motor will damage the controller. Always inspect the motor before replacing the controller. See External Motor Testing, Section 17, Page 17-1. NOTE: The software is subject to frequent updates, and this manual spans many versions.
Page 422 IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH Faults Menu ERIC CHARGING The vehicle speed controller should be checked for fault codes before any service is performed. The speed controller, after detecting a fault, will respond in one or more of the following ways: •...
Page 423: Fault Recovery
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH ERIC CHARGING Faults Menu FAULT RECOVERY When a fault is detected by the speed controller, the speed controller will attempt to recover from the fault and resume normal operation. In the case of an intermittent problem such as a loose wiring connection, the controller may be able to recover and operate normally for a while, but the problem should be repaired before placing the vehicle in service.
Page 424: Fault Descriptions
The max password tries fault is declared when the incorrect password fault has been declared several times. In the event that the max password tries fault is indicated, the speed controller must be removed and shipped to Club Car before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 27-5. See also Password Tries (IQDM-P Only) on page 26-8.
Page 425: Thermal Cutback
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH ERIC CHARGING Faults Menu THERMAL CUTBACK If the controller heatsink temperature is found to be in excess of 185 °F (±9) (85 °C (±5)) or below –13 °F (±9) (–25 °C (±5)), the thermal cutback fault is detected.
Page 426: Main Welded
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH Faults Menu ERIC CHARGING What it means: This is a symptom, not a cause. The controller records the number of times this occurs. What to do: Charge batteries. If fault occurs more frequently than normal, test battery pack. See Section 30 – Batteries: Electric Vehicle with ERIC Charging.
Page 427: Main Dropout (1 Or 2)
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH ERIC CHARGING Faults Menu MAIN DROPOUT (1 OR 2) If the controller detects that the solenoid contacts have opened while the vehicle is in operation, a main dropout fault is detected. What it means: Occurs when the solenoid coil losses ground causing the main contact to lose connection.
Page 428: Hw Failsafe
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH Functions Menu ERIC CHARGING CAUTION • A failed motor will ruin a controller. If a new controller is installed in a vehicle with a bad motor, the bad motor will blow the field FET in the new controller. Always check the motor before replacing a controller when a FLD Missing fault is shown.
Page 429 IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH ERIC CHARGING Functions Menu settings have been transferred to the handset, the technician can then connect the handset to another vehicle and transfer the stored settings into the speed controller. Speed Controller Cloning –...
Page 430: Write Settings To Controller
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH Functions Menu ERIC CHARGING Figure 26-4 Handset Executing Figure 26-5 Confirmation Message WRITE SETTINGS TO CONTROLLER This function transfers all of the speed controller settings (except for “private speed mode”) from the handset to the vehicle speed controller.
Page 431: Reset All Settings
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH ERIC CHARGING Functions Menu Select write settings to controller. Press “+” on the change value button to confirm the operation. The handset will display an “executing...” message for the next few seconds while the controller settings are being stored in the handset’s memory (Figure 26-4, Page 26-18).
Page 432: Information
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH Information ERIC CHARGING The handset will display an “executing...” message for the next few seconds while the controller settings are being stored in the handset’s memory (Figure 26-4, Page 26-18). When the handset is finished resetting the speed controller settings, a confirmation message is displayed (Figure 26-7, Page 26-19).
Page 433: Programmer Setup
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH ERIC CHARGING Programmer Setup PROGRAMMER SETUP The programmer setup menu selection allows the user to set the LCD display contrast, records the fault history of the handset, and displays information pertaining to the handset. PROGRAM This menu allows the user to adjust the contrast on the display screen.
Page 434 IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH IQDM and IQDM-P Handset Troubleshooting ERIC CHARGING IQDM AND IQDM-P HANDSET TROUBLESHOOTING In the event that the handset does not function as described in this manual, the following troubleshooting guide should be studied and the referenced test procedures should be performed to troubleshoot the handset.
Page 435: Test Procedures
IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH ERIC CHARGING Test Procedures TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Disconnect the IQDM cord from the vehicle. Handset malfunction Wait a few seconds and reconnect the handset to the vehicle See Section 30 –...
Page 436 IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH Test Procedures ERIC CHARGING The procedure for testing the handset cord adaptor is similar to the cord test. Using a multimeter set for 200 ohms, place the red (+) probe into one of the terminals on the end of the adapter with the square plug.
Page 437 IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM WITH ERIC CHARGING Test Procedures 4.2. Remove electronics module cover. See Electronics Module Cover on page 29-5. 4.3. Connect IQDM to controller. 4.3.1. Disconnect the square four-pin connector (3) from the speed controller. 4.3.2.
Page 439: Section 27 - Iq Display Module Programmer (Iqdm-P): Excel System With Eric Charging
SECTION 27 – IQ DISPLAY MODULE PROGRAMMER (IQDM-P): EXCEL SYSTEM WITH ERIC CHARGING DANGER • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. NOTE: For information pertaining to the introductory display, menu navigation, and monitor, faults and function menus, see IQ Display Module (IQDM) and IQDM-P Diagnostics: Excel System with ERIC Charging on page 26-1.
Page 440: Program Menu
IQ DISPLAY MODULE PROGRAMMER (IQDM-P): Program Menu EXCEL SYSTEM WITH ERIC CHARGING PROGRAM MENU The program menu can be accessed by pressing the right arrow on the navigation button when the square beside program is blinking (Figure 27-3, Page 27-2). When the program menu is active, use the up or down arrows on the navigation button to go to the desired item in the program menu.
Page 441: Settings
IQ DISPLAY MODULE PROGRAMMER (IQDM-P): EXCEL SYSTEM WITH ERIC CHARGING Program Menu SETTINGS Speed Setting The vehicle’s top speed can be changed by selecting values 1 through 3 (Figure 27-4, Page 27-2). If a value of 4 is displayed for the speed setting, a special access code has been entered to place the vehicle in “private speed mode.” A speed setting of 4 cannot be selected with the speed setting menu item.
Page 442 IQ DISPLAY MODULE PROGRAMMER (IQDM-P): Program Menu EXCEL SYSTEM WITH ERIC CHARGING S3 FWD Speed The s3 fwd speed option allows for adjustability of the SPEED 3 speed setting. From the factory, s3 fwd speed will be set to one of 4 options: 12.4, 13.2, 14.0 and 14.8 mph (20.0, 21.3, 22.6 and 23.8 km/h, respectively). The default s3 fwd speed is 14.8 mph (23.8 km/h).
Page 443: Amp Hours
ANSI Z130.1 – American National Standard for Golf Cars – Safety and Performance Specifications because it is capable of speeds in excess of 15 mph (24.1 km/h). For more information on this feature, contact your local Club Car distributor or dealer. VEHICLE ID NOTE: If controller is replaced, the information below must be entered into the new controller.
Page 445: Section 28 - Excel System Troubleshooting: With Eric Charging
SECTION 28 – EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING DANGER • See General Warnings on page 1-2. WARNING • See General Warnings on page 1-2. • Shorting of battery terminals can cause personal injury or death. – Do not place component mounting plate directly on top of batteries when removing or installing plate.
Page 446: Attributes Of The Excel System
EXCEL SYSTEM TROUBLESHOOTING: General Information WITH ERIC CHARGING ATTRIBUTES OF THE EXCEL SYSTEM • Excel is used in Precedent models only. • Excel utilizes the 1515 controller instead of the 1510A. • The Excel 1515 controller uses half-bridge technology allowing cooler operating temperatures and increased motor braking.
Page 447: Features
EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING General Information FEATURES • Shunt-Wound Motor: The shunt-wound motor, unlike a series motor, is designed so that the speed controller is able to vary the amount of current passing through the field coils independently from the current passing through the armature.
Page 448: Wiring Diagrams
EXCEL SYSTEM TROUBLESHOOTING: Wiring Diagrams WITH ERIC CHARGING WIRING DIAGRAMS RUN/TOW SW ITCH FORWARD/REVERS E (FNR) SW ITCH WD1040232_DGM_B-L Figure 28-1 Wiring Diagram – Excel System with ERIC Charging Page 28-4 2014 Precedent ® Golf Car Maintenance and Service Manual...
Page 449 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Wiring Diagrams 30 A WD1040232_DGM_B-R Figure 28-2 Wiring Diagram – Excel System with ERIC Charging (Continued) 2014 Precedent ® Golf Car Maintenance and Service Manual Page 28-5...
Page 450 EXCEL SYSTEM TROUBLESHOOTING: Wiring Diagrams WITH ERIC CHARGING BATTERY CHARGING OP TIONAL INDICATOR SWITCH NOTE: SOME WIRING / COMPONENTS S HOWN ARE OPTIONAL ACCESSORIES WD1039915_DGM_C1 Figure 28-3 Instrument Panel Wiring Diagram – Precedent with ERIC Charging Page 28-6 2014 Precedent ®...
Page 451 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Wiring Diagrams To Solenoid Lead for DC-DC Converter To B- Terminal on Controller WD_6x8V_Batteries_ERIC_Charging Figure 28-4 Battery Wiring Diagram – Precedent with ERIC Charging 2014 Precedent ® Golf Car Maintenance and Service Manual Page 28-7...
Page 452 EXCEL SYSTEM TROUBLESHOOTING: Wiring Diagrams WITH ERIC CHARGING USED WHEN THERE ARE LIGHTS BUT NO TURN S IGNAL. NORMALLY OPEN MOM ENTARY PUSH BU TTON FOR HORN 9-PIN #16 ORANGE CONNECT OR #16 BLUE/WHITE #16 WHITE #16 YELLOW SONIC #16 BROWN/WHITE WELD FLASHER UNIT...
Page 453 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Wiring Diagrams HEADLIGHT ASSEMBLY DC - DC HORN CONVERTER SONIC 20 AMP WELD #16 BLACK FUS E SONIC WELD #18 O RANGE DIODE #16 BLACK/WHITE #12 BLACK SON IC WELD #16 BLACK SON IC WELD CONNE CTS TO MAIN HARNESS.
Page 454 EXCEL SYSTEM TROUBLESHOOTING: Wiring Diagrams WITH ERIC CHARGING To Connected To Instument Car Device Panel Harness (i.e. Guardian 9-Pin Connector or Visage) Sonic We ld To MCOR Sonic Forward/ Reverse We ld Switch Sonic We ld 10k Ohm Resistor Sonic We ld Sonic We ld...
Page 455: Troubleshooting
TROUBLESHOOTING THE VEHICLE WITH THE IQDM Club Car recommends the use of the IQDM handset for troubleshooting vehicles equipped with the Excel electrical system. Troubleshooting Guide 1 is to be used in conjunction with the IQDM handset. See IQ Display Module (IQDM) and IQDM-P Diagnostics: Excel System with ERIC Charging on page 26-1 for operating instructions.
Page 456 EXCEL SYSTEM TROUBLESHOOTING: Troubleshooting WITH ERIC CHARGING TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected motor speed sensor Repair and/or connect the three-pin connector or broken wire to the motor speed sensor Monitor Menu – SPEED PULSES menu item indicates that speed pulses are OFF when Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector...
Page 457 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected three-pin connector at Repair and/or connect the three-pin connector the MCOR or broken wire to the MCOR Diagnostic Menu – THROTTLE FAULT fault Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector code...
Page 458: Troubleshooting Guide 2
EXCEL SYSTEM TROUBLESHOOTING: Troubleshooting WITH ERIC CHARGING TROUBLESHOOTING GUIDE 2 In the event that the vehicle is not functioning properly after completing Troubleshooting Guide 1, use Troubleshooting Guide 2. If an IQDM handset is unavailable, use Troubleshooting Guide 2. TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION...
Page 459 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Troubleshooting TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Test Procedure 12 – Motor Speed Sensor on Speed sensor disconnected or failed page 28-29 To change the programmed top speed of the Incorrect speed setting vehicle, an IQDM-P handset must be used Check vehicle wiring.
Page 460: Test Procedures
EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING TEST PROCEDURES Using the following procedures, the entire electrical system can be tested without major disassembly of the vehicle. WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.
Page 461 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Test Procedures CAUTION • Be careful not to damage the wire or terminal when back-probing. • When testing voltage, the batteries must remain connected. • When testing voltage, unless specifically directed to do otherwise in a procedure, connect the black (–) probe of the multimeter to the negative post of battery no.
Page 462 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING installed in reverse polarity. Refer to Batteries: Electric Vehicle with ERIC Charging on page 30-1 for further details on battery testing. NOTE: The voltage displayed through the IQDM shows what the controller thinks it sees. If the controller is not operating properly, it may display a different voltage from what the battery pack voltage (BPV) really is.
Page 463 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Test Procedures (Viewed from driver side of vehicle) 1. RED probe to battery no. 1 (+). 2. BLACK probe to battery no. 6 (-). 2500-30100-10411 Figure 28-9 Battery Discharge Test Turn the discharge machine on and record the voltage reading of battery pack while under load. A fully charged set of batteries in good condition should read between 46 and 49 volts while under load.
Page 464 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING If the IQDM display screen begins to work, proceed to step 5; otherwise, perform the following procedure, Tow/Run Switch Test without the IQDM Handset. With the IQDM still connected to vehicle, place Tow/Run Switch in TOW position. If the IQDM display screen goes blank, the Tow/Run switch and connecting wires are operating correctly.
Page 465 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Test Procedures 3.4. If the pink wire side does not show BPV, make sure Tow/Run switch in the RUN position. If it is in RUN, inspect Tow/Run switch, red-to-pink wire spade connector near the solenoid, and sonic welds 5 and 8. TEST PROCEDURE 5 –...
Page 466 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING NOTE: The easiest way to test the key switch and MCOR Limit Switch is to check the pin 6 green wire in the 16-pin connector. Pin 6 is the end of this circuit. 4.1.
Page 467 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Test Procedures page 28-4. Also check the 16-pin connector at the speed controller. See Test Procedure 15 – 16-Pin Connector on page 28-32. Test REVERSE INPUT. 4.1. Access the Monitor menu and select REVERSE INPUT by using the SCROLL DISPLAY buttons. The IQDM should indicate OFF when the Forward/Reverse switch is in the NEUTRAL or FORWARD position.
Page 468 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING TEST PROCEDURE 7 – Solenoid Activating Coil See General Warnings on page 1-2. NOTE: This is a resistance test. Be aware that one of two different solenoids may be found on the vehicle. Visually, the production solenoid is smaller than the service replacement.
Page 469 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Test Procedures TEST PROCEDURE 9 – Solenoid Continuity See General Warnings on page 1-2. Solenoid Continuity Test with the IQDM Handset If necessary, see Testing Basics on page 28-16. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands under the frame rails just forward of each spring mount.
Page 470 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING TEST PROCEDURE 10 – Charger Interlock See General Warnings on page 1-2. Controller Interlock Function Test with the IQDM Handset If necessary, see Testing Basics on page 28-16. Connect the IQDM to the vehicle. Access the Monitor menu and select CHARGER INHIBIT by using the SCROLL DISPLAY buttons.
Page 471 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Test Procedures TEST PROCEDURE 11 – MCOR Voltage See General Warnings on page 1-2. NOTE: This is a voltage test. The accelerator position, which is proportional to the MCOR voltage, can be displayed with the IQDM handset. If an IQDM handset is not available, proceed to MCOR Voltage Test without the IQDM Handset.
Page 472 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING WARNING • The key switch should be placed in the OFF position and left in the OFF position for the duration of this test. With the batteries connected, place Tow/Run switch in RUN. Using a multimeter set to 200 volts DC, place red (+) probe on battery no.
Page 473 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Test Procedures TEST PROCEDURE 12 – Motor Speed Sensor See General Warnings on page 1-2. Motor Speed Sensor Test without any Tool CAUTION • Perform the following procedure only on a level surface. To avoid injury or property damage, ensure that the path of the vehicle is clear before pushing vehicle.
Page 474 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING 4.1. With Tow/Run switch in the RUN position and using a multimeter set to 20 volts DC, place the black (–) probe on the battery no. 6 (6 x 8-Volt battery set) negative post and place red (+) probe on red wire terminal socket in three-pin connector.
Page 475 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Test Procedures As the accelerator pedal is pressed, the voltage reading should increase from approximately 5 volts RMS when the MCOR limit switch closes, to approximately 48 volts RMS with the accelerator pedal fully pressed. See following NOTE.
Page 476 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING TEST PROCEDURE 15 – 16-Pin Connector See General Warnings on page 1-2. Pin 1 – White Pin 5 – Light Blue Pin 9 – Gray Pin 13 – White/Black Pin 2 – Yellow Pin 6 –...
Page 477 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Test Procedures With Tow/Run switch in the TOW position, reconnect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4. Place the Tow/Run switch in the RUN position and then check the appropriate wires. If 16-pin must be connected: Disconnect the batteries and discharge the controller.
Page 478 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING PERFORM TEST WITH 16-PIN CONTROLLER INPUTS CONNECTED TO CONTROLLER? (IF TEST PROCEDURE YES, BACK-PROBE TO TEST) KEY SWITCH INPUT BPV from Key switch in ON Pin 10 – Tan SOLENOID INPUT BPV from Solenoid Activating Coil (result of Pin 12 –...
Page 479 EXCEL SYSTEM TROUBLESHOOTING: WITH ERIC CHARGING Test Procedures Place the Tow/Run switch in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4. Place the key switch in the OFF position and the Tow/Run switch in the RUN position. Using a multimeter set to 200 volts DC, place the black (–) probe on battery no.
Page 480 EXCEL SYSTEM TROUBLESHOOTING: Test Procedures WITH ERIC CHARGING TEST PROCEDURE 18 – 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 –...
Page 481: Section 29 - Electrical Components: Electric Vehicle With Eric Charging
SECTION 29 – ELECTRICAL COMPONENTS: ELECTRIC VEHICLE WITH ERIC CHARGING DANGER • 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 the appropriate troubleshooting section for the type of electrical system used in the vehicle. See Test Procedure 5 –...
Page 482: Charge Indicator Light
ELECTRICAL COMPONENTS: ELECTRIC Charge Indicator Light VEHICLE WITH ERIC CHARGING 3.3. Secure instrument panel to the dash assembly with three screws (1). Tighten screws to 1.8 ft·lb (2.5 N·m). Connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4. Figure 29-1 Instrument Panel Removal Figure 29-2 Key Switch CHARGE INDICATOR LIGHT...
Page 483: Charge Indicator Light Installation
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE WITH ERIC CHARGING Forward/Reverse Rocker Switch CHARGE INDICATOR LIGHT INSTALLATION Install in reverse order of removal. Place the Tow/Run switch in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4. 2787 Figure 29-3 Charge Indicator Light FORWARD/REVERSE ROCKER SWITCH...
Page 484: Forward/Reverse Rocker Switch Installation
ELECTRICAL COMPONENTS: ELECTRIC Forward/Reverse Rocker Switch VEHICLE WITH ERIC CHARGING Figure 29-4 Forward/Reverse Rocker Switch FORWARD/REVERSE ROCKER SWITCH INSTALLATION Route the three wires through bezel. Connect the blue (4), orange (5) and brown (6) wires to the rocker switch (3), exactly as shown in (Figure 29-4, Page 29-4). Orient the rocker switch (3) so the terminals are towards the front of the housing (1).
Page 485: Electronics Module Cover
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE WITH ERIC CHARGING Electronics Module Cover ELECTRONICS MODULE COVER See General Warnings on page 1-2. The electronics module cover needs to be removed to gain access to the speed controller, Tow/Run switch, and solenoid. ELECTRONICS MODULE COVER REMOVAL Disconnect the batteries and discharge the controller.
Page 486: Tow/Run Switch
ELECTRICAL COMPONENTS: ELECTRIC Tow/Run Switch VEHICLE WITH ERIC CHARGING Figure 29-5 Access and Remove Electronics Module Cover TOW/RUN SWITCH See General Warnings on page 1-2. TESTING THE TOW/RUN SWITCH See Test Procedure 3 – Tow/Run Switch on page 28-19. TOW/RUN SWITCH REMOVAL Disconnect the batteries and discharge the controller.
Page 487: Motor Controller Output Regulator (Mcor)
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE WITH ERIC CHARGING Motor Controller Output Regulator (MCOR) Figure 29-6 Tow/Run Switch MOTOR CONTROLLER OUTPUT REGULATOR (MCOR) See General Warnings on page 1-2. TESTING THE MCOR See Test Procedure 11 – MCOR Voltage on page 28-27 and Test Procedure 5 – Key Switch and MCOR Limit Switch Circuit on page 28-21.
Page 488: Reverse Buzzer
ELECTRICAL COMPONENTS: ELECTRIC Reverse Buzzer VEHICLE WITH ERIC CHARGING REVERSE BUZZER See General Warnings on page 1-2. TESTING THE REVERSE BUZZER See 28-34. REVERSE BUZZER REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4.
Page 489: Electronics Module
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE WITH ERIC CHARGING Electronics Module ELECTRONICS MODULE See General Warnings on page 1-2. While it is not necessary to remove the electronics module from the vehicle, access to individual components may be easier with the module removed. ELECTRONICS MODULE REMOVAL Disconnect the batteries and discharge the controller (1).
Page 490: Electronics Module Installation
ELECTRICAL COMPONENTS: ELECTRIC Electronics Module VEHICLE WITH ERIC CHARGING 2771 Figure 29-8 Controller and Solenoid Removal ELECTRONICS MODULE INSTALLATION Return electronics module (3) to its location in vehicle but leave it tilted forward. Complete connections to the controller (1), the Tow/Run switch (5) and the solenoid (4) per the electrical schematics.
Page 491: Speed Controller
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE WITH ERIC CHARGING Speed Controller Install the batteries and battery cables in their original locations. See Battery Replacement on page 30-5. Place the Tow/Run switch (5) in the TOW position and connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-4.
Page 492: Solenoid
7.6. Select Program, Vehicle ID, Vehicle Date of Manufacture and enter the number on the model year and week from the vehicle serial number. 7.7. Select Information, Software Version and verify the value is 13 or higher. If not, contact a Club Car Technical Representative.
Page 493: Solenoid Removal
ELECTRICAL COMPONENTS: ELECTRIC VEHICLE WITH ERIC CHARGING Charger Receptacle SOLENOID REMOVAL Disconnect the batteries and discharge the controller (1). See Disconnecting the Batteries – Electric Vehicles on page 1-4. Remove the electronics module cover (8) to access the solenoid (4). See Electronics Module Cover Removal on page 29-5.
Page 494: Charger Receptacle Removal
ELECTRICAL COMPONENTS: ELECTRIC Charger Receptacle VEHICLE WITH ERIC CHARGING CHARGER RECEPTACLE REMOVAL Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4. Remove kick plate. See Kick Plate and Charger Receptacle Bezel on page 4-9. Remove the 10-gauge red wire from the solenoid .
Page 495: Section 30 - Batteries: Electric Vehicle With Eric Charging
SECTION 30 – BATTERIES: ELECTRIC VEHICLE WITH ERIC CHARGING DANGER • 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 496: Battery Testing Basics - 8 Volt
BATTERIES: ELECTRIC VEHICLE WITH Battery Testing Basics – 8 Volt ERIC CHARGING BATTERY TESTING BASICS – 8 VOLT See General Warnings on page 1-2. OBSERVATION Inspect the battery compartment for the following items: • Rusted, corroded, or broken battery posts •...
Page 497: Battery Testing - 8 Volt
BATTERY REGROUPING 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 498 BATTERIES: ELECTRIC VEHICLE WITH Battery Regrouping ERIC CHARGING BATTERY REGROUPING PROCESS FLOW (6 volt, 8 volt, and 12 volt batteries) 1. In s ta ll a ll n e w b a tte rie s o r a ll re g ro u p a b le b a tte rie s ; d o n o t m ix n e w with re g ro u p a b le e xc e p t fo r th e la s t c a r re g ro u p e d .
Page 499: Battery Replacement
BATTERIES: ELECTRIC VEHICLE WITH ERIC CHARGING 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°...
Page 500: 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 501: Battery Care - Vehicles Equipped With The Single-Point Watering System
BATTERIES: ELECTRIC VEHICLE WITH ERIC CHARGING Battery Care ALLOWABLE CONTENT (PARTS IMPURITY EFFECTS OF IMPURITY PER MILLION) Suspended matter Trace Total solids 100.0 Organic and volatile matter 50.0 Corrosion of positive plates Ammonia Slight self-discharge of both plates Self-discharge, reduces life, lower Antimony on-charge voltage Arsenic...
Page 502: Battery Care - Vehicles Without The Single-Point Watering System
BATTERIES: ELECTRIC VEHICLE WITH Battery Care ERIC CHARGING WARNING • If battery wire terminals are damaged or corroded, replace or clean them as necessary. Failure to do so may cause them to overheat during operation and could result in fire, property damage, or personal injury.
Page 503: Self-Discharge
BATTERIES: ELECTRIC VEHICLE WITH ERIC CHARGING Battery Care CAUTION • Do not overfill the batteries. NOTE: A battery watering gun or bottle is available at many auto parts dealers. The battery hold-downs should be tight enough so that the batteries do not move while the vehicle is in motion, but not so tight as to crack or buckle the battery case.
Page 504: Vibration Damage
BATTERIES: ELECTRIC VEHICLE WITH Battery Care ERIC CHARGING CAUTION 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 30-3 Battery Electrolyte Level Add water only after charging unless the electrolyte is below the level of the plates.
Page 505: Single Point Watering System (Spws)
A deionizer for vehicles with SPWS, Club Car Part Number AM1240701 (110/115 volt AC), is available from Service Parts. Replacement cartridge: AM1240801. Bottled distilled water, with hand pump, Club Car Part Number AM1238501, is recommended for private consumer applications.
Page 506 BATTERIES: ELECTRIC VEHICLE WITH Single Point Watering System (SPWS) ERIC CHARGING Figure 30-4 Connecting Hose with Filter to Water Source Figure 30-5 Checking the Water Flow Rate Completely open the water faucet until the water flows out of the hose-end assembly (3), and note the movement of the red flow indicator balls (6).
Page 507: Battery Storage
BATTERIES: ELECTRIC VEHICLE WITH ERIC CHARGING Battery Storage 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. When the red flow indicator balls stop moving, immediately press the grey button to disconnect the hose-end assembly from the battery fill coupling (9), and squeeze the dust cover (10) to lightly secure it to the male connector of the battery fill coupling (Figure 30-6, Page 30-12).
Page 509: Section 31 - Battery Charger: For Eric Charging System
WARNING • Only trained technicians should repair or service the charger. Contact your nearest Club Car distributor/dealer. • This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.
Page 510: General Information
IC0650-048-COMM). Do not attempt to service a battery charger that has not been properly identified. If a charger cannot be properly identified, contact your local Club Car dealer or distributor. How To Identify A Vehicle That Uses This High-Frequency Charger •...
Page 511: Usb Service Port
USB SERVICE PORT The charger has a USB port for use by Club Car authorized technicians for data transfer, reconfiguration, and updates. Keep the USB port cover in place when the port is not in use.
Page 512: Charger Power Connection Fuse
BATTERY CHARGER: FOR ERIC CHARG- General Information ING SYSTEM WARNING • If pins are bent, the plug must be replaced immediately. The plug is not serviceable. Do not attempt to repair the plug or straighten bent pins. • Disconnect the AC cord prior to lubricating the plug and receptacle. NOTE: If the warning tag has been damaged or removed from the DC cord, have it replaced immediately.
Page 513: Charger Status Indicators
BATTERY CHARGER: FOR ERIC CHARGING SYSTEM General Information CHARGER STATUS INDICATORS The indicator lights on the charger provides information concerning charger status. LIGHT STATUS STATUS EXPLANATION Charger error. Reset charger power. See Resetting Power – External Solid red Charger on page 31-14. Flashing orange Charger unable to complete charge.
Page 514: External Charger Mounting
BATTERY CHARGER: FOR ERIC CHARG- External Charger Mounting ING SYSTEM EXTERNAL CHARGER MOUNTING WARNING • Make sure the charger is securely mounted. Do not hang the charger by its handle. • Place all cords so they will not be stepped on, tripped over, or otherwise subjected to damage or stress. CAUTION •...
Page 515: Ac Power Connection
NOTE: Make sure that the AC cord provided with your charger has the proper AC plug for your location. If it does not, contact your Club Car representative to obtain the proper cord or plug. Two of these high-frequency chargers can be used on a dedicated 15 or 20 ampere, single-phase branch circuit. This...
Page 516: The Charge Circuit
BATTERY CHARGER: FOR ERIC CHARG- The Charge Circuit ING SYSTEM 240 VAC and 50 to 60 Hz ranges. The charger also will function outside of those ranges (down to 85 VAC and 40 Hz, up to 270 VAC and 70 Hz) although charging times will be longer. Outside of the 85 to 270 VAC and 40 to 70 Hz ranges, the charger will not operate.
Page 517: Charger Operation
BATTERY CHARGER: FOR ERIC CHARGING SYSTEM Charger Operation Onboard Charger: The charge circuit consists of the charger receptacle, interlock wire, controller, solenoid and battery pack (Figure 31-7, Page 31-9). FRONT OF VEHICLE Battery Pack Voltage (+) BATTERY BANK Pull-up Resistor (10k Ohm) CONTROLLER B–...
Page 518 Vehicles should be restricted to 40 to 50 amp hours of discharge (or 36 holes of golf) between charges until the batteries have been properly seasoned (50 to 70 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 deeply discharging the batteries.
Page 519 If the charger does not seem to be operating properly, or if the batteries seem weak, see Charger Troubleshooting on page 31-13. If troubleshooting does not solve the issue, contact your local Club Car distributor/dealer. Figure 31-8 Correct Insertion of External Charger DC Plug...
Page 520: Charger Maintenance
BATTERY CHARGER: FOR ERIC CHARG- Charger Maintenance ING SYSTEM CHARGER MAINTENANCE See General Warnings on page 1-2. To ensure trouble-free performance, it is very important to follow an established preventive maintenance program. Regular and consistent maintenance can prevent vehicle downtime and expensive repairs that can result from neglect. Any charger not functioning correctly should be removed from use until it is properly repaired.
Page 521: Charger Troubleshooting
BATTERY CHARGER: FOR ERIC CHARGING SYSTEM Charger Troubleshooting 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 522: Terminal Block Cover
When the blue AC status indicator light comes on, reconnect the DC cord under the rear-facing seat. If the triangular status indicator light comes on, contact your Club Car dealer. If the light does not come back on, attempt to charge the vehicle as usual.
Page 523: Charger Troubleshooting Indicators
BATTERY CHARGER: FOR ERIC CHARGING SYSTEM Charger Troubleshooting CHARGER TROUBLESHOOTING INDICATORS If a fault occurs, count the number of red flashes (on the charger or dash) between pauses and refer to the table below: HIGH-FREQUENCY BATTERY CHARGER TROUBLESHOOTING GUIDE CHECK STATUS STATUS POSSIBLE CAUSES...
Page 524: Test Procedures
BATTERY CHARGER: FOR ERIC CHARG- Test Procedures ING SYSTEM HIGH-FREQUENCY BATTERY CHARGER TROUBLESHOOTING GUIDE Inspect charger receptacle, receptacle harness connections and DC cord connection to charger. See DC Plug and 9. Bad DC connection Receptacle on page 31-16. See Charger DC Circuit Continuity Test on page 31-18.
Page 525 BATTERY CHARGER: FOR ERIC CHARGING SYSTEM Test Procedures 3.3. Verify that the 16-gauge light blue wire from the charger receptacle is connected to the light blue wire bullet connector from the main wire harness. With batteries connected, DC cord disconnected, and using a multimeter set to 200 volts DC, place the black (–) probe in the charger receptacle socket connected to the black 10-gauge wire and place the red (+) probe in the charger receptacle socket connected to the red 10-gauge wire.
Page 526 BATTERY CHARGER: FOR ERIC CHARG- Test Procedures ING SYSTEM If the charger will not power ON, check AC cord connections. If the charger is connected correctly, check continuity of the AC cord wires. TEST PROCEDURE 6 – Charger DC Circuit Continuity Test Disconnect the AC cord from the wall outlet and the DC cord from the vehicle charger receptacle.
Page 527: External Charger Repairs
BATTERY CHARGER: FOR ERIC CHARGING SYSTEM External Charger Repairs EXTERNAL CHARGER REPAIRS See General Warnings on page 1-2. WARNING • Knowledge of battery charger wiring and component terminology is required before attempting any repair (Figure 31-6, Page 31-8). • Prior to servicing the charger, disconnect the DC plug from the vehicle charger receptacle and the AC cord from the AC outlet.
Page 528: Terminal Block Cover Installation
BATTERY CHARGER: FOR ERIC CHARG- External Charger Repairs ING SYSTEM 2791 Figure 31-11 Terminal Block Cover Mounting Tabs TERMINAL BLOCK COVER INSTALLATION WARNING • The terminal block cover (3) on the DC terminal block (4) must be installed properly to comply with UL code.
Page 529: Handle Removal
BATTERY CHARGER: FOR ERIC CHARGING SYSTEM External Charger Repairs HANDLE REMOVAL Remove torx screws (8) securing handle (9) to charger. HANDLE INSTALLATION Place handle (9) onto charger and seat it onto mounting bosses of charger. See following NOTE. NOTE: The handle (9) features locating tabs to aid installation. Secure handle (9) to charger with two torx screws (8).
Page 530: Onboard Charger Repairs
BATTERY CHARGER: FOR ERIC CHARG- Onboard Charger Repairs ING SYSTEM ONBOARD CHARGER REPAIRS WARNING • Knowledge of battery charger wiring and component terminology is required before attempting any repair (Figure 31-7, Page 31-9). • Prior to servicing the charger, disconnect the DC plug from the vehicle charger receptacle and the AC cord from the AC outlet.
Page 531: Onboard Charger Installation
BATTERY CHARGER: FOR ERIC CHARGING SYSTEM Onboard Charger Repairs Disconnect DC charging harness (6) from onboard charger DC cord (7). Disconnect 14-pin plug (8) from onboard charger (4). Remove two torx screws (9) securing DC cord connector (7) to seat bottom (2). Retain insulator (10). Remove two torx screws (11) securing charger shield (12) to onboard charger (4).
Page 532: Dc Cord And Strain Relief Removal
BATTERY CHARGER: FOR ERIC CHARG- Onboard Charger Repairs ING SYSTEM 2793 Figure 31-13 Terminal Block Cover, DC Cord and Strain Relief – Onboard Charger DC CORD AND STRAIN RELIEF REMOVAL Disconnect AC cord from AC outlet. Disconnect DC cord (1) at connector mounted under seat (Figure 31-13, Page 31-24). Remove terminal block cover.
Page 533: Dc Charging Harness Installation
BATTERY CHARGER: FOR ERIC CHARGING SYSTEM Onboard Charger Repairs Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles on page 1-4. Lift rear-facing seat bottom and support in the raised position. Disconnect DC charging harness from onboard charger DC cord. Disconnect 14-pin plug from onboard charger.
Page 535 INDEX charging ..........20-31–20-32 hydrometer test ..........19-12 AC power and circuit installation ............20-32 testing (ERIC charger) ........31-17 load test............19-14 accelerator maintenance ........... 20-29 cable mineral content ..........20-30 installation ............. 22-8 removal ............20-31 removal ............22-8 self-discharge ..........
Page 536 INDEX removal ............6-1 communication display module (CDM) braking, motor function codes..........13-38 see regenerative braking ......13-2, 28-3 retrieving data from ......... 13-39 braking, regenerative troubleshooting ..........13-40 see regenerative braking ......13-2, 28-3 connector, 16-pin breather valve (reed valve) ........21-3 see test procedures .......
Page 537 INDEX electrical system (Excel with PowerDrive charger) removal ............22-14 features ............13-2 fuel gauge/hour meter general information..........13-1 fuel gauge circuit ..........19-11 testing circuits ..........13-13 testing ............19-32 electrical system (gasoline vehicle) .......19-11 fuel level sending unit engine ignition circuit ........19-11 testing ............
Page 538 INDEX inspection IQDM-P drive clutch ............25-6 Excel system drive clutch parts.......... 25-10 amp hours ............. 27-5 driven clutch ........... 25-14 anti-tamper speed .......... 27-4 front wheel free play .......... 7-14 audible charging indicator ....... 27-5 motor battery type ........... 27-5 armature ground test ........
Page 539 INDEX periodic lubrication schedule ......10-7 periodic service schedule........10-4 oil level sensor motor ..........13-2, 17-1, 28-3 installation ..........20-27, 21-6 armature removal ..........20-27, 21-6 ground test ............ 17-9 testing ............19-30 inspection............17-8 oil light assembly ............17-13 see also low oil warning light ......19-11 bearing onboard computer (OBC) ........
Page 540 INDEX installation ........14-8, 20-19, 29-8 armature............20-4 limit switch ground test ............ 20-8 installation ........... 20-20 armature inspection ........... 20-6 removal ............20-20 assembly ..........20-4, 20-9 removal ......... 14-8, 20-19, 29-8 bearing testing ........13-36, 19-30, 28-34 cleaning ............20-6 RPM adjustment ...........22-6, 22-9 inspection............
Page 541 INDEX lubrication ............7-6 MCOR3 limit switch ......... 13-20 toe-in adjustment..........7-7 motor, A1 and A2 voltage......... 13-18 wheel alignment ..........7-6 OBC gray wire and fuse........13-33 suspension, rear OBC, rebooting ..........13-37 shock absorber onboard computer SCR ........13-32 inspection and removal........
Page 542 INDEX see service tools ..........24-3 torque converter Valve Clearance Check and Adjustment....21-3 troubleshooting ..........25-2 Visage Tow/Run switch ..........13-2, 28-3 connector, 4-pin installation ..........14-6, 29-6 see test procedures........28-36 removal ............14-6, 29-6 voltage regulator testing ..........13-19, 28-19 installation ............
Page 546 5. If you are reviewing a Kit Instruction, were all indicated parts included in your kit? Yes / No Your Comments and Suggestions: Please send a copy of this page to: Fax: (706) 228-2662 or Thank You! E-mail: Tech_Pubs@clubcar.com Club Car’s Technical Publications Department 2014 Precedent ® Golf Car Maintenance and Service Manual...

Club Car Precedent 2014 Maintenance And Service Manual

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