Club Car IQ PLUS SYSTEM Maintenance Service Supplement
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Club Car IQ PLUS SYSTEM Maintenance Service Supplement

Club Car IQ PLUS SYSTEM Maintenance Service Supplement

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2006
MAINTENANCE
SERVICE
SUPPLEMENT
IQ PLUS SYSTEM
ELECTRIC VEHICLES
MANUAL NUMBER 102907708
EDITION CODE 0906A00000

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Summary of Contents for Club Car IQ PLUS SYSTEM

  • Page 1 2006 MAINTENANCE SERVICE SUPPLEMENT IQ PLUS SYSTEM ELECTRIC VEHICLES MANUAL NUMBER 102907708 EDITION CODE 0906A00000...
  • Page 3 If it appears that a service question is not answered in this supplement, you may write to us at: Club Car, Inc., P.O. Box 204658; Augusta, Georgia 30917-4658, USA, Attention: Technical Services, or contact a Club Car Technical Service Representative at (706) 863-3000, ext.
  • Page 4 NOTE: This supplement represents the most current information at the time of publication. Club Car, Inc. is continually working to further improve its vehicles and other products. These improvements may affect servicing procedures.

  • Page 5: Table Of Contents

    Communication Display Module (CDM) .................... 11-45 Using the CDM to Retrieve Data from the Onboard Computer ............ 11-46 CDM Troubleshooting Guide ......................11-47 SECTION 12 – IQ PLUS SYSTEM DISPLAY MODULE (IQDM SERIES 2) DIAGNOSTICS Plugging the Handset into the Vehicle ....................12-1 Introductory Display ..........................
  • Page 6 14-7 Battery Testing ..........................14-8 Battery Charger Test ........................14-8 On-Charge Voltage Test ......................14-8 Hydrometer Test ........................... 14-8 Discharge Test ..........................14-10 Battery Troubleshooting Examples ....................14-12 Page iv 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 7 17-7 Transaxle Assembly ........................17-9 Transaxle Installation ........................17-10 SECTION 18 – IQ PLUS SYSTEM DISPLAY MODULE (IQDM-P SERIES 2) PROGRAM- MING Plugging the Handset into the Vehicle ....................18-1 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 8 Program Menu ..........................18-2 M1/M2 Speed ..........................18-2 M1/M2 Fast Accel ......................... 18-3 M1/M2 Pedal Up ........................... 18-3 M1/M2 Speed Cal ......................... 18-4 Code A, Code B, and Code C ...................... 18-5 Functions Menu ..........................18-5 Get Settings From Controller ......................18-5 Write Settings to Controller ......................

  • Page 9: Section 10 - Periodic Maintenance

    • Ensure battery connections are clean and properly tightened. See Battery Care on page 14-3. • Place Tow/Run switch in the TOW position before disconnecting or connecting the batteries. WARNING CONTINUED ON NEXT PAGE... 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 10-1...
  • Page 10 Figure 10-1 Battery Configuration (Transporter 4 and Figure 10-2 Battery Configuration (Villager 6 and 8) 6, Carryall 6) Page 10-2 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 11: General Information

    This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic ser- vice. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 12: Periodic Service Schedule

    • If any problems are found during scheduled inspection or service, do not operate the vehicle until repairs are made. Failure to make necessary repairs could result in fire, property damage, severe personal injury, or death. Page 10-4 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 13: Periodic Lubrication Schedule

    (or every 100 hours of Inspect front wheel bearings operation, whichever Chassis Lube – EP NLGI Grade 2 (Repack as necessary) comes first) FLOORBOARD Figure 10-4 Vehicle Lubrication Points 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 10-5...

  • Page 15: Section 11 - Electrical System And Testing

    • See General Warning, Section 10, Page 10-1. GENERAL INFORMATION The IQ Plus System vehicle uses a 48-volt electrical system that is powered by eight 6-volt lead-acid batteries and includes an onboard computer. The IQ Plus System vehicle uses a shunt-wound 3.7 hp motor and includes several additional features.

  • Page 16: Wiring Diagrams

    ELECTRICAL SYSTEM AND TESTING Wiring Diagrams WIRING DIAGRAMS CARRYALL 2, TURF 2 VEHICLES Figure 11-1 Wiring Diagram –Carryall 2, Turf 2 Vehicles Page 11-2 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 17 ELECTRICAL SYSTEM AND TESTING Wiring Diagrams Figure 11-2 Wiring Diagram –Carryall 2, Turf 2 Vehicles 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11-3...
  • Page 18 (PIN 8) GREEN : TO MCOR LIMIT SWITCH (PIN 4) GRAY : TO TOW SWITCH Figure 11-3 Wiring Diagram – Carryall 6, Villager 6, Transporter 4 and 6 Vehicles Page 11-4 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 19 18_PINK(W15) ON-BOARD CHARGER CONNECTOR 18_YEL(W29) COMPUTER FIELD 3 PIN CONNECTOR 4_WHT(W01) 18_BLK_WHT(W43) 18_YEL_BLK_STP(W38) 10_BLK(W39) Figure 11-4 Wiring Diagram – Carryall 6, Villager 6, Transporter 4 and 6 Vehicles 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11-5...
  • Page 20 ELECTRICAL SYSTEM AND TESTING Wiring Diagrams VILLAGER 8 VEHICLE Figure 11-5 Wiring Diagram –Villager 8 Vehicle Page 11-6 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 21 ELECTRICAL SYSTEM AND TESTING Wiring Diagrams Figure 11-6 Wiring Diagram –Villager 8 Vehicle 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11-7...

  • Page 22: Troubleshooting

    TROUBLESHOOTING THE VEHICLE WITH THE IQDM Club Car recommends the use of the IQDM handset for troubleshooting vehicles equipped with the IQ Plus electrical system. Troubleshooting Guide 1 is to be used in conjunction with the IQDM handset. Refer to the IQDM Owner’s Manual for operating instructions.

  • Page 23: Troubleshooting Guide 1

    Test Procedure 16 – Forward/Reverse Failed Forward/Reverse rocker switch Rocker Switch on page 11-41 Troubleshooting Guide continued on next page... 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11-9...
  • Page 24 Replace the speed controller. See Speed Failure of the FET that controls the Controller Removal, Section 13, solenoid coil Page 13-11. Troubleshooting Guide continued on next page... Page 11-10 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 25 Failure of the motor armature or brushes Section 16 – Motor (Model DA5-4006) Replace the speed controller. See Speed Failure of the FET’s that control armature Controller Removal, Section 13, current Page 13-11. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11-11...

  • Page 26: Troubleshooting Guide 2

    Test Procedure 6 – Tow/Run Switch on Failed Tow/Run switch page 11-21 Replace speed controller. See Speed Speed controller failure Controller Removal, Section 13, Page 13-11. Troubleshooting Guide continued on next page... Page 11-12 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 27 Battery voltage below 32 volts Charge batteries Test Procedure 12 – Onboard Computer Blown fuse at charger receptacle Gray Wire and Fuse on page 11-37 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11-13...

  • Page 28: Test Procedures

    14. Motor Speed Sensor 15. Solenoid Contacts 16. Forward/Reverse Rocker Switch 17. Reverse Buzzer 18. Rebooting the Onboard Computer 19. Battery Warning Light 20. Zero Speed Detect Relay Page 11-14 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 29 TRANSPORTER 4 AND 6 VILLAGER 6 AND 8 CARRYALL 6 FRONT OF VEHICLE FRONT OF VEHICLE TURF 2 CARRYALL 2 battery cables. FRONT OF VEHICLE Figure 11-7 IQ Plus Battery Configurations 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11-15...
  • Page 30 If connections are correct, OBC activation circuit has failed. Replace OBC. Figure 11-8 Test Blue OBC Wire (+) Figure 11-9 Test Light Blue 18-Gauge Wire at 24-pin Connector (+) Page 11-16 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 31 4. If a failed diode was removed, replacement of the diode is not necessary because a diode that serves the same function is located within the speed controller. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V SOLENOID 2k OHM SETTING Figure 11-10 Activating Coil Test 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11-17...
  • Page 32 (1) at a point close to the three-pin connector at the MCOR (Figure 11-11). The reading should be approximately 48-50 volts (full battery voltage). Figure 11-11 Test MCOR: Purple/White Wire (+) Page 11-18 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 33 8. If the reading is not approximately 4.60 volts with the pedal fully pressed, the vehicle will not operate at rated top speed. Check the MCOR resistance. 8.1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally start- 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11-19...
  • Page 34 When the pedal is all the way to the floor, the multimeter should indicate approximately 1k ohms. 8.9. If the MCOR does not operate as described, replace the MCOR. Page 11-20 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 35 5. If the IQDM display screen begins to work after the vehicle has been driven, turn the key switch to the OFF position and proceed to step 6; otherwise, perform the following procedure, Tow/Run Switch Test without the IQDM Handset. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11-21...
  • Page 36 5. If the two-pin connector and pink wire continuity readings are correct, replace the Tow/Run switch. Figure 11-16 Test Continuity: Pink Wire on Solenoid Figure 11-17 Test Continuity: Two-pin Connector Post Page 11-22 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 37 Key Switch and MCOR Limit Switch Circuit Test without the IQDM Handset. If the key switch functions as described, proceed to the following step. See following NOTE. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11-23...
  • Page 38 48 volts (full battery voltage). 5.3. If the voltage reading is 48 volts when the accelerator pedal is not pressed, check the pedal group Page 11-24 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 39 If the results of any of the referenced procedures are different from those described in the procedure, check the continuity of the wires in the wire harness and test the connected components with the appropriate test procedures. See Index of Test Procedures on page 11-14. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11-25...
  • Page 40 24-pin connector. See following CAUTION. Insert the black (–) probe into pin 14 (purple/white wire) of the 24-pin connector (Figure 11-13, Page 11-19). CAUTION • Do not fully insert probes into the 24-pin plug. Doing so can result in a poor connection. Page 11-26 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 41 10. If any other reading is observed, check the continuity of the wires in the wire harness. Detail: Front of 24-Pin Connector Figure 11-18 Test: Pins 14 and 15 (Purple/White and Yellow wires) 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11-27...
  • Page 42 • Onboard computer for proper operation. See Test Procedure 12 – Onboard Computer Gray Wire and Fuse on page 11-37. • Tow/Run switch for proper operation. See Test Procedure 6 – Tow/Run Switch on page 11-21. Page 11-28 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 43 ELECTRICAL SYSTEM AND TESTING Troubleshooting Detail: Front of 24-Pin Connector Figure 11-19 Test: Pin 2 (Light Blue Wire) 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11-29...
  • Page 44 9. After a short delay, the onboard computer should power-up (come out of sleep mode). 10. The multimeter should indicate full battery voltage (approximately 48 volts) when the accelerator pedal is pressed. Page 11-30 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 45 8. If any other activity is observed, check the following items: • Continuity of the wires in the wire harness • Reverse buzzer for proper operation. See Test Procedure 17 – Reverse Buzzer on page 11-42. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11-31...
  • Page 46 The multimeter should indicate zero volts DC at this time. 7. While monitoring the multimeter, place the Forward/Reverse switch in the REVERSE position. The mul- timeter should still indicate zero volts. Page 11-32 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 47 +48 volt signal to the speed controller through pin 1 (tan wire) when the key switch is in the ON position. 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 10, Page 10-1. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11-33...
  • Page 48 • Tow/Run switch for proper operation. See Test Procedure 6 – Tow/Run Switch on page 11-21. • Key switch for proper operation. See Test Procedure 9 – Key Switch and MCOR Limit Switch Cir- cuit on page 11-23. Page 11-34 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 49 2. The reading should be 48 volts. If the reading is zero volts, check the purple wire continuity from the key switch to the 24 pin connector. If there is no continuity, replace the keyswitch. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11-35...
  • Page 50 • Red wire at the charger receptacle. See Test Procedure 13 – Voltage at Charger Receptacle Red Wire Socket on page 11-37. Figure 11-24 Test 10: OBC Silicon-Controlled Rectifier Circuit Page 11-36 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 51 10-gauge wire. The reading should be 48-50 volts (full battery voltage). 2. If the reading is zero volts, check the continuity of the 10-gauge red wire from the positive post of battery no. 1 to the receptacle socket. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11-37...
  • Page 52 3.2. If the reading is zero volts, check the continuity of the black/white wire from the 24-pin connector at the speed controller to the three-pin connector at the motor speed sensor. If the continuity is cor- rect, replace the speed controller. Page 11-38 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 53 If the continuity is cor- rect, replace the speed controller. 5.3. If reading is below 3.50 volts, check the continuity of the wires and plug and replace the speed con- 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11-39...
  • Page 54 6.2. Replace the speed sensor if • there is no voltage reading. • the voltage reading is not above 3.50. • the voltage reading does not fluctuate as the motor is turned. Page 11-40 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 55 2 position. With the switch in NEUTRAL or REVERSE, there should be no continuity. With the switch in FORWARD, there should be continuity. If the readings are incorrect, replace the switch. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11-41...
  • Page 56 6.4. If the orange/white wire continuity and 24-Pin connector are correct and there is no voltage at the orange wire, replace the controller. Page 11-42 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 57 6. Install the wedge lock in the six-pin connector housing and reconnect the six-pin connector plug. Place the Tow/Run switch in the RUN position and the battery light should illuminate. If the light does not illu- minate, replace the battery warning light assembly. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11-43...
  • Page 58 Motor Speed Sensor. See Test Procedure 14 – Motor Speed Sensor on page 11-38. If the Motor Speed Sensor is operational, replace the Zero Speed Detect Relay. Page 11-44 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 59: Communication Display Module (Cdm)

    The CDM can be used to retrieve from the onboard computer four important items of information that can be useful in troubleshooting the IQ Plus System vehicle. To access one of these items, the item’s corresponding Function Code must be selected on the CDM. This is done by pressing the Function Button until the desired function code is displayed in the window.

  • Page 60: Using The Cdm To Retrieve Data From The Onboard Computer

    • To view F4, press and hold the button on the CDM until “Func 4” appears in the display window. Release the button. The value for F4 will be displayed. NOTE: The values of all four functions can be recalled by pressing and releasing the CDM button. Page 11-46 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 61: Cdm Troubleshooting Guide

    Troubleshooting CDM TROUBLESHOOTING GUIDE Use the following chart as a starting point for troubleshooting problems with communication between the CDM and onboard computer. Contact your Club Car representative for more comprehensive information. OBC Will Not Communicate With The CDM CDM battery...

  • Page 63: Section 12 - Iq Plus System Display Module (Iqdm Series 2) Diagnostics

    4. Remove the dust cap from the IQDM jack. 5. Align the keyed portion of the plug with the IQDM jack and connect the plug to the jack. Figure 12-1 Connector Under Forward/Reverse Switch 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 12-1...

  • Page 64: Introductory Display

    “bookmark set” is displayed. When it is necessary to go back to the bookmarked screen, rapidly press and release the appropriate bookmark button. See following NOTE. Page 12-2 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 65 The faults menu displays all faults recorded by the speed controller since the history was last cleared. Each fault is listed only once, even if the fault has occurred multiple times. See Faults Menu on page 12-8. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 12-3...

  • Page 66: Monitor Menu

    85 °C ±5 °C (185 °F ±9 °F). See following NOTE. NOTE: Improper brake adjustment can sometimes cause the operating current to be higher than normal. This higher current increases the temperature of the speed controller heatsink. Page 12-4 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 67 Mode 2. In the event that Mode 2 is locked out, the controller must be removed and shipped to Club Car before Mode 2 can be activated. See Code A, Code B, and Code C, Section 18, Page 18-5.
  • Page 68 Displays the number of times the MOTOR STALL fault has been detected. See Fault Descriptions on page 12-11. Main DRVR Off# Displays the number of times the MAIN DRVR OFF fault has been detected. See Fault Descriptions on page 12-11. Page 12-6 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 69 Displays the number of miles the vehicle has been driven in units of 10 miles. Miles x 1 Displays the number of miles the vehicle has been driven in units of single miles. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 12-7...

  • Page 70: Faults Menu

    The speed controller, after detecting a fault, will respond in one or more of the following ways: 1. Reduce vehicle speed to zero by reducing armature current to zero 2. Reduce vehicle speed to zero by reducing field current to zero Page 12-8 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 71: Fault Recovery

    Depending on the type of fault, the controller will attempt to recover immediately after the condition clears or after the accelerator pedal has been cycled (released and pressed again). 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 12-9...
  • Page 72 At power up, after SmartKey Cycle Tow/Run TRIES codes entered Condition clears in Walk- 29 RELAY DRVR OFF WalkAway 2,13 Away 30 RELAY COIL FAULT Continuous Condition clears Page 12-10 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 73: Fault Descriptions

    IQ PLUS SYSTEM DISPLAY MODULE (IQDM SERIES 2) DIAGNOSTICS Faults Menu FAULT DESCRIPTIONS The following faults can be detected by the IQ Plus System controller: 01 Throttle Fault 1 If the MCOR (Motor Controller Output Regulator) voltage is less than 0.20 volts or greater than 4.80 volts, the controller detects a throttle fault.
  • Page 74 In the event that the max password tries fault is indicated, the speed controller must be removed and shipped to Club Car before it can ever be placed in Mode 2. See Code A, Code B, and Code C, Section 18, Page 18-5.

  • Page 75: Clearing Fault History

    See Clear Fault History on page 12-14. INFORMATION The information menu is accessed by using the up or down arrow to scroll to information and pressing the right arrow key to activate the menu. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 12-13...

  • Page 76: Programmer Setup

    This menu displays any faults that have been detected within the handset itself. Clear Fault History The clear fault history function will erase the history of handset faults that are stored in the handset. Page 12-14 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 77: Information

    Loose vehicle wire harness connections page 12-17 See Section 11 – Electrical System and Speed controller malfunction Testing. Handset has failed Replace handset Troubleshooting Guide continued on next page... 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 12-15...

  • Page 78: Test Procedures

    The following test procedures enable the technician to test the IQDM-P Series 2 handset and the components of the IQ Plus System vehicle that are related to the proper operation of the handset. This diagnostics section does not contain detailed information for troubleshooting the vehicle. Refer to the vehicle maintenance and service manual for detailed vehicle troubleshooting and service procedures.
  • Page 79 (When Located on Vehicle F&R Switch) on page 12-18. To test directly at the speed controller, see Test Procedure 3B – IQDM Jack (At Speed Controller) on page 12-18. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 12-17...
  • Page 80 1. Check the IQDM jack on the speed controller. 1.1. Remove the three bolts securing the speed controller access panel and remove the access panel. 1.2. Disconnect the square four-pin connector (1) from the speed controller. Page 12-18 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 81 Procedure 2 – Handset Cord Adaptor on page 12-17. The IQDM jacks and connections should also be thoroughly checked. See Section 11 – Electrical System and Testing. Figure 12-4 Disconnect Four-pin Connector. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 12-19...
  • Page 82 IQ PLUS SYSTEM DISPLAY MODULE (IQDM SERIES 2) DIAGNOSTICS Test Procedures Page 12-20 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 83: Section 13 - Electrical Components

    2.3. Insert screwdriver at the top center of the dash between dash and cowl brace. Gently pry center dash out slightly from under edge of cowl brace. Figure 13-1 Dash Removal 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 13-1...
  • Page 84 3. Install center dash by reversing removal procedure. Make sure key switch terminals (7) do not touch frame and that the center dash panel is properly seated and snapped into place (Figure 13-2, Page 13-2). Page 13-2 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 85: Forward/Reverse Rocker Switch

    REVERSE position. The reverse buzzer will sound as a warning when the Forward/Reverse switch is in REVERSE. • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 13-3...

  • Page 86: Tow/Run Switch

    2. Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first. Tighten battery terminals to 110 in-lb (12.4 N·m) and coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion. Page 13-4 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 87: Circuit Breaker

    4. Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first. Tighten battery terminals to 110 in-lb (12.4 N·m) and coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion. Figure 13-4 Circuit Breaker 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 13-5...

  • Page 88: Motor Controller Output Regulator (Mcor)

    6. Push the drive bar (4) into the hole in the I-beam to disengage it from the accelerator pivot rod (5). Figure 13-5 Motor Controller Output Regulator (MCOR) Mounting Page 13-6 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 89: Reverse Buzzer

    1. Use a flathead screwdriver to pry up the center pieces of the 3 push rivets (1) and remove the rivets (Figure 13-6, Page 13-8). 2. Pull the speed controller cover (2) down and away from the component mounting plate. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 13-7...

  • Page 90: Solenoid

    3. Disconnect all wires from the solenoid (Figure 13-7, Page 13-9). 4. Loosen, but do not remove, the two screws (1) that hold the solenoid (2) to the component mounting plate. Page 13-8 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 91 6. Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first. Tighten battery terminals to 110 in-lb (12.4 N·m) and coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 13-9...

  • Page 92: Onboard Computer (Obc)

    1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 10, Page 10-1. 2. Remove the speed controller cover. See Removing the Speed Controller Cover on page 13-7. Page 13-10 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 93: Solid State Speed Controller

    General Warning, Section 10, Page 10-1. 2. Remove the speed controller cover. See Removing the Speed Controller Cover on page 13-7. 3. Disconnect all wires and multi-pin connectors from the speed controller. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 13-11...
  • Page 94 REVERSE position. The reverse buzzer will sound as a warning when the Forward/Reverse switch is in REVERSE. • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. Page 13-12 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 95: Charger Receptacle

    2. Remove the 10-gauge red wire from the connector plug (10) (Figure 13-11, Page 13-15). 3. Remove black 10-gauge OBC wire from charger receptacle. 4. Disconnect the gray wire from the receptacle at the yellow fuse holder (9). 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 13-13...
  • Page 96 7. Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first. Tighten battery terminals to 110 in-lb (12.4 N·m) and coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion. Page 13-14 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 97: Receptacle Fuse Link

    RECEPTACLE FUSE LINK The fuse link on the 48-volt Club Car electric vehicle should not blow under normal operating conditions; how- ever, if the fuse link has blown, the vehicle will not charge and the fuse must be replaced. The fuse link (6) is mounted on top of the charger receptacle in the battery compartment (Figure 13-11, Page 13-15).

  • Page 98: Battery Warning Light

    2. Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first. Tighten battery terminals to 110 in-lb (12.4 N·m) and coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion. Figure 13-12 Battery Warning Light Page 13-16 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 99: Section 14 - Batteries

    The outward appearance of these two batteries is similar, but the operating characteristics are very different. The Club Car electric vehicle battery is a deep-cycle battery, and the automotive battery is a “starting, lighting and ignition” (SLI) battery. They should never be substituted for one another.
  • Page 100 FRONT OF VEHICLE Place Tow/Run switch in the TOW position before disconnecting or connecting battery cables. Remove negative cable first. Figure 14-3 Battery Configuration (Turf 2, Carryall 2) Page 14-2 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 101: Battery Care

    Contaminants on dirty batteries can provide a path for a small current draw that can slowly discharge batter- ies, thus wasting valuable energy. To prevent self-discharge, batteries should always be kept clean. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 14-3...

  • Page 102: Electrolyte Level

    For best results, use a battery watering gun to add water to batteries. Check the electrolyte level more frequently in hot weather or when batteries are old. Page 14-4 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 103: Mineral Content

    IQ Plus vehicles will damage the batteries. The charger supplied with the Club Car electric vehicle resolves the most common problems associated with battery charging. Undercharging and overcharging are prevented provided the charger is allowed to shut off by itself.

  • Page 104: Deep-Discharge

    The deeper the discharge, the harder it is on the batteries. For this reason, it is recommended that Club Car electric vehicle batteries be charged after each use (pro- vided the charge cycle will not be interrupted and the charger will be allowed to shut off automatically). Placing the batteries on charge after each use reduces the depth of discharge and prolongs battery life.

  • Page 105: Battery Troubleshooting Chart

    If discharge time is 60 minutes or If discharge time is less than 60 minutes, replace all batteries below 5.0 V. more, problem is not with the batteries. Figure 14-5 Battery Troubleshooting Chart 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 14-7...

  • Page 106: Battery Testing

    4. When the float rises off the bottom, adjust the electrolyte level so that the float rides free of the bottom but does not strike the top of the glass tube. Remove the hydrometer from the cell and release the pres- sure from the bulb. Page 14-8 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 107 If the difference between the cells is 0.020 or more, the low cell should be suspected. It may require a catch- up charge or it may be a weak cell. When the variations between cells reach 0.050 or more, the battery with the low cell should be replaced. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 14-9...

  • Page 108: Discharge Test

    Measure and record the voltage of each battery to the near- est 0.01 volt. See following NOTE. NOTE: The tester will shut off automatically when shut-off voltage is reached. Page 14-10 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 109 57 Minutes 72 Minutes (21-23 °C) (49-54 °C) 75-79 °F 130-150 °F 60 Minutes 74 Minutes (24-26 °C) (54-66 °C) 80-84 °F 62 Minutes ***** ***** (27-29 °C) 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 14-11...

  • Page 110: Battery Troubleshooting Examples

    Battery no. 2 should be replaced with a bat- tery that has the same age and usage as the other batteries in the set. Page 14-12 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 111: Battery Storage

    80 °F (26.7 °C) will have to be recharged every few weeks. 5. 48-volt Club Car electric vehicles and compatible battery chargers are designed to be left connected, with AC power to the charger ON, during off-season storage. The storage charge feature will automati- cally charge the batteries as needed throughout the storage period.

  • Page 113: Section 15 - Battery Charger

    SECTION 15 – BATTERY CHARGER Refer to the appropriate battery charger maintenance and service manual. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 15-1...

  • Page 115: Section 16 - Motor (Model Da5-4006)

    • See General Warning, Section 10, Page 10-1. GENERAL INFORMATION The IQ Plus System vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. This 3.7 horsepower motor is designed for use on IQ Plus System vehicles only. Club Car recommends that motors requiring major repair be sent to a qualified motor repair shop;...

  • Page 116: Motor

    Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor. When not performing a test or service procedure that requires movement of the wheels, lock the brakes. Page 16-2 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 117 Fingers may get pinched when motor disengages. 10. Carefully slide the motor away from the transaxle until the motor spline disengages the input shaft and remove the motor from the vehicle. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 16-3...

  • Page 118: Motor Disassembly

    5. Remove the four end cap bolts. The weight of the motor housing will cause it to drop when the bolts are removed. See following Caution. ý CAUTION • The motor housing will drop when the bolts are removed. Do not put fingers under the motor Page 16-4 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 119 13.1. Remove the retaining ring that secures the bearing in the end cap (Figure 16-9, Page 16-6). 13.2. Use an arbor press to remove the bearing from the end cap. 14. Inspect the bearing for wear and damage. See Bearing Inspection on page 16-9. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 16-5...

  • Page 120: Motor Component Testing And Inspection

    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 16-6 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 121: Motor Frame And Field Windings Inspection

    3. Inspect the brush springs (18) (Figure 16-13, Page 16-10). Replace springs that are discolored from heat (light gold or blue tinted). 4. Test the brush springs for proper tension. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 16-7...
  • Page 122 4. Use dial calipers or a micrometer to measure the brush length. The minimum-allowable brush length is 0.62 inches (16 mm). Replace the set of brushes as required. See preceding NOTE. Page 16-8 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 123 Figure 16-12 Bearing Inspection Speed Sensor Magnet Inspection Inspect the speed sensor magnet (12) for rust, wear, and cracks (Figure 16-13, Page 16-10). Replace the magnet if necessary. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 16-9...
  • Page 124 MOTOR (MODEL DA5-4006) Motor Component Testing and Inspection MOTOR MOUNTING TYPICAL 3 PLACES Figure 16-13 Motor Page 16-10 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 125: Reconditioning The Motor

    Tighten nuts to 100 in-lb (11.3 N·m). Ensure that the terminal posts do not rotate when tightening the nuts. 2.4. Secure the brush rigging to the end cap with four bolts. Tighten the bolts to 25 in-lb (2.8 N·m). 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 16-11...

  • Page 126: Motor Installation

    2.3. Apply motor coupling grease evenly to the rotating input shaft starting at approximately 1/8 inch (3.1 mm) from the end of the shaft and working back toward the transaxle (away from the end of the Page 16-12 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 127 When the motor is pushed onto the input shaft, the motor housing will not bottom out against the transaxle housing. There will be approximately 1/16 inch (1.6 mm) gap between the motor adapter ring and transaxle housing as shown (Figure 16-19, Page 16-14). 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 16-13...
  • Page 128 7. If removed, install wheels and finger tighten the lug nuts. 8. Lift vehicle and remove jack stands. Lower vehicle to the floor and tighten lug nuts, using a crisscross pat- tern, to 55 ft-lb (74.6 N·m). Page 16-14 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 129 Reverse switch is in REVERSE. • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. VIEWED FROM DRIVER SIDE Figure 16-20 Motor Mount 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 16-15...

  • Page 131: Section 17 - Transaxle (Type G)

    • 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. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 17-1...
  • Page 132 Figure 17-1 Axle Tube Figure 17-2 Axle Seal and Adapter Ring Removal ADAPTER RING LIP Figure 17-3 Axle Seal and Adapter Ring Figure 17-4 Axle Seal and Adapter Ring Installation Page 17-2 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 133 TRANSAXLE (TYPE G) Axle Bearing and Shaft TYPICAL 6 PLACES Figure 17-5 Transaxle – Type G 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 17-3...

  • Page 134: Axle Bearing

    Do not remove the axle bearing (5) from a Type G transaxle. If bearing is worn or damaged, the entire axle assembly (1 or 2) must be replaced (Figure 17-5, Page 17-3). Page 17-4 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 135: Transaxle

    Figure 17-6 Vehicle Supported on Jack Stands Figure 17-7 Brake Cables Remove bolts, then rotate shackles up and away from spring. Figure 17-8 Disconnect Shocks Figure 17-9 Shackles 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 17-5...
  • Page 136 NOTE: Recycle or dispose of used oil or lubricant in accordance with local, state, and federal regulations. 15. Remove the brake assemblies if required. See Section 6 – Wheel Brake Assemblies in the appropri- ate maintenance and service manual. Page 17-6 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 137: Transaxle Disassembly, Inspection, And Assembly

    • Do not reuse bearings after removing them. Replace bearings with new ones. 6. To disassemble the intermediate gear assembly, press off together the bearing (16) and the gear (19) (Figure 17-5, Page 17-3). See also Figure 17-13, Page 17-8. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 17-7...
  • Page 138 8.4. Remove the differential pin (31) by pushing pin through differential gear case from one side (Figure 17-5, Page 17-3). See also Figure 17-15, Page 17-9. 8.5. Remove the idler gears and thrust plates (1 and 2) (Figure 17-16, Page 17-9). Page 17-8 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 139: Transaxle Assembly

    6. Install the differential assembly, the intermediate gear assembly, and the input pinion gear simulta- neously. Be sure all bearings are seated properly in the housing. Rotate the input shaft to check for smooth gear operation (Figure 17-11, Page 17-6). 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 17-9...

  • Page 140: Transaxle Installation

    2. Align the center hole in the saddle of the transaxle with the pilot bolt in the leaf spring assembly. Page 17-10 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 141 REVERSE position. The reverse buzzer will sound as a warning when the Forward/ Reverse switch is in REVERSE. • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 17-11...

  • Page 143: Section 18 - Iq Plus System Display Module (Iqdm-P Series 2) Program

    4. Remove the dust cap from the IQDM jack located on the vehicle below the Forward/Reverse switch. 5. Align the keyed portion of the plug with the IQDM jack and connect the plug to the jack. Figure 18-1 Connector Under Forward/Reverse Switch 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 18-1...

  • Page 144: Program Menu

    A vehicle programmed for speed setting 4 does not conform to ANSI Z130.1 – American National Standard for Golf Cars – Safety and Performance Specifications because it is capable of speeds in excess of 15 mph (24.1 km/h). For more information on this feature, contact your local Club Car distributor or dealer. Page 18-2...

  • Page 145: M1/M2 Fast Accel

    M1/M2 PEDAL UP SETTING MODE OPERATION DESCRIPTION Pedal up motor braking is disabled Mild pedal up Mild pedal up motor braking Aggressive pedal up Aggressive pedal up motor braking 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 18-3...

  • Page 146: M1/M2 Speed Cal

    9.1 mph (14.6 km/h) 12.1 mph (19.5 km/h) 14.1 mph (22.7 km/h) 5.0 mph (8.0 km/h) 9.0 mph (14.5 km/h) 12.0 mph (19.3 km/h) 14.0 mph (22.5 km/h) Page 18-4 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

  • Page 147: Code A, Code B, And Code C

    Once activated, Mode 2 settings can be programmed using the same procedures as Mode 1 settings. This allows the vehicle to be customized to perform according to which mode it is operated in. For more informa- tion on this feature, contact your local Club Car distributor or dealer. To activate Mode 2: 1.

  • Page 148: Write Settings To Controller

    10. With the controller settings stored in the memory of the handset, the handset can be used to transfer all of the desired speed controller settings to any IQ Plus System vehicle or group of IQ Plus System vehi- cles. See Speed Controller Cloning – Transferring Settings from the Handset to the Vehicle on page 18-6.

  • Page 149: Reset All Settings

    5. The handset will display an “executing...” message for the next few seconds while the controller settings are being stored in the handset’s memory. 6. When the handset is finished resetting the speed controller settings, a confirmation message is dis- played. 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 18-7...
  • Page 151 ........16-9 braking, motor transaxle, type g ..........17-7 see regenerative braking IQDM braking, regenerative functions menu ..........18-5 see regenerative braking introductory display ..........12-2 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page i-1...
  • Page 152 ............11-38 1 – batteries/voltage check ......11-15 speed sensor magnet 2 – onboard computer solenoid lockout circuit 11-16 inspection ............ 16-9 3 – solenoid activating coil ......11-17 Page i-2 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...
  • Page 153 ..........11-2 battery troubleshooting examples ....14-12 communication display module (CDM) ..11-47 troubleshooting guide 1 ........11-9 troubleshooting guide 2 ........11-12 troubleshooting IQDM ........12-15 water level see batteries, electrolyte level 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page i-3...

  • Page 154: Section I - Index

    2. Ease of Finding Information 3. Clarity of Illustrations 4. Index Usability 5. Troubleshooting Chart Usability Comments/Suggestions Please fax a copy of this page to (706) 228-2662. Thank You! Club Car Technical Publication Department 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement...

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