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Club Car IQ Plus 2008 Maintenance And Service Manual Supplement

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2008-2011 IQ Plus
Maintenance and Service
Manual Supplement
IQ Plus
Electric Vehicles
Manual Number 103373107
Edition Code 1107B1210A

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Summary of Contents for Club Car IQ Plus 2008

  • Page 1 2008-2011 IQ Plus Maintenance and Service Manual Supplement IQ Plus Electric Vehicles Manual Number 103373107 Edition Code 1107B1210A...
  • Page 3 Club Car distributor/dealer representative or by a Club Car factory-trained tech- nician. It is the policy of Club Car, LLC to assist its distributors and dealers in continually updating their service knowl- edge and facilities so they can provide prompt and efficient service for vehicle owners. Regional technical rep- resentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and other service publications also represent Club Car’s continuing commitment to customer support.
  • Page 4 NOTE: This supplement represents the most current information at the time of publication. Club Car, LLC is continually working to further improve its vehicles and other products. These improvements may affect servicing procedures.

  • Page 5: Table Of Contents

    CONTENTS SECTION 10 – PERIODIC MAINTENANCE General Warning ..........................10-1 Disabling The Vehicle ........................10-3 Disconnecting The Batteries ......................10-3 Connecting The Batteries ......................10-3 General Information .......................... 10-4 Periodic Service Schedule ........................ 10-4 Periodic Lubrication Schedule ......................10-6 SECTION 11 – ELECTRICAL SYSTEM AND TESTING General Information ..........................
  • Page 6 Programmer Setup ........................... 12-18 Program ............................12-18 Faults ............................12-18 Information ........................... 12-18 IQDM and IQDM-P Handset Troubleshooting .................. 12-19 Test Procedures ..........................12-20 Index of Test Procedures ......................12-20 SECTION 13 – ELECTRICAL COMPONENTS Key Switch ............................13-1 Forward/Reverse Rocker Switch ...................... 13-3 Tow/Run Switch ..........................
  • Page 7 Battery Troubleshooting Chart ......................14-9 Battery Testing ..........................14-10 Battery Charger Test ........................14-10 On-Charge Voltage Test ....................... 14-10 Hydrometer Test ........................... 14-10 Discharge Test ..........................14-12 Battery Troubleshooting Examples ....................14-14 Battery Storage ..........................14-15 Charging a Battery Pack that has Low Voltage ................14-15 SECTION 15 –...
  • Page 8 SECTION 18 – IQ DISPLAY MODULE (IQDM-P) SERIES 2 PROGRAMMING Plugging the Handset into the Vehicle ..................... 18-1 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 ......................

  • Page 9: Section 10 - Periodic Maintenance

    SECTION 10 – PERIODIC MAINTENANCE GENERAL WARNING The following safety statements must be heeded whenever the vehicle is being operated, repaired, or ser- viced. Service technicians should become familiar with these general safety statements, which can be found throughout this manual. Also, other specific safety statements appear throughout this manual and on the vehi- cle.
  • Page 10 PERIODIC MAINTENANCE General Warning ý WARNING • To avoid unintentionally starting the vehicle, place Tow/Run switch in the TOW position, then disconnect the batteries as shown (See Figures 10-1, 10-2, or 10-3 beginning on page 10-2). • After disconnecting the batteries, wait 90 seconds for the controller capacitors to discharge. •...

  • Page 11: Disabling The Vehicle

    PERIODIC MAINTENANCE General Warning (–) Figure 10-3 Battery Configuration (Turf 2, Carryall 2, Carryall 6 (Style B)) (Viewed from driver side of vehicle) 1. Place TOW/RUN Switch in TOW before disconnecting or connecting battery cables. 2. Remove negative battery cable. 3.

  • Page 12: General Information

    This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic ser- vice. PERIODIC SERVICE SCHEDULE ý...
  • Page 13 PERIODIC MAINTENANCE Periodic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Daily service by owner See Pre-Operation and Daily Safety Pre-Operation and Daily Safety Checklist Checklist in the appropriate Owner’s Manual See Performance Inspection in the Performance Inspection appropriate Owner’s Manual Batteries Charge batteries (after each use only).

  • Page 14: Periodic Lubrication Schedule

    PERIODIC MAINTENANCE Periodic Lubrication Schedule PERIODIC LUBRICATION SCHEDULE See General Warning on page 10-1. PERIODIC LUBRICATION SCHEDULE LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Semiannually by owner Brake pedal shaft bearings Dry Moly Lube (CC P/N 1012151) or trained technician (or every 50 hours of Brake linkage and pivots Dry Moly Lube (CC P/N 1012151)

  • Page 15: Section 11 - Electrical System And Testing

    If no speed settings are programmed, motor braking will be activated at any time accelerator is released, and it will only dis- engage when the vehicle comes to a stop. Contact your Club Car dealer/distributor to inquire about this programmable feature.

  • Page 16: Wiring Diagrams

    ELECTRICAL SYSTEM AND TESTING Wiring Diagrams WIRING DIAGRAMS 000566-001 Figure 11-1 Wiring Diagram – Carryall 2 and Turf 2 Vehicles Page 11-2 2008-2011 IQ Plus Electric Vehicle Maintenance and Service Supplement...
  • Page 17 ELECTRICAL SYSTEM AND TESTING Wiring Diagrams 000566-001 Figure 11-2 Wiring Diagram – Carryall 2 and Turf 2 Vehicles 2008-2011 IQ Plus Electric Vehicle Maintenance and Service Supplement Page 11-3...
  • Page 18 ELECTRICAL SYSTEM AND TESTING Wiring Diagrams (PIN 9) PINK : TO RELAY COIL B+ 000580-001 (PIN 8) GREEN : TO MCOR LIMIT SWITCH Figure 11-3 Wiring Diagram – Carryall 6, Transporter 4 and 6 Vehicles Page 11-4 2008-2011 IQ Plus Electric Vehicle Maintenance and Service Supplement...
  • Page 19 ELECTRICAL SYSTEM AND TESTING Wiring Diagrams 000580-001 Figure 11-4 Wiring Diagram – Carryall 6, Transporter 4 and 6 Vehicles 2008-2011 IQ Plus Electric Vehicle Maintenance and Service Supplement Page 11-5...
  • Page 20 ELECTRICAL SYSTEM AND TESTING Wiring Diagrams (PIN 9) PINK : TO RELAY COIL B+ 000581-001 (PIN 8) GREEN : TO MCOR LIMIT SWITCH Figure 11-5 Wiring Diagram – Villager 6 and 8 Vehicles Page 11-6 2008-2011 IQ Plus Electric Vehicle Maintenance and Service Supplement...
  • Page 21 ELECTRICAL SYSTEM AND TESTING Wiring Diagrams 000581-001 Figure 11-6 Wiring Diagram – Villager 6 and 8 Vehicles 2008-2011 IQ Plus 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

    ELECTRICAL SYSTEM AND TESTING Troubleshooting TROUBLESHOOTING GUIDE 1 The following troubleshooting guide is intended for use with an IQDM handset. For IQDM operating instruc- tions, refer to the IQDM Owner’s Manual. See following NOTE. NOTE: Before troubleshooting the vehicle, check the diagnostic history from the Special Diagnostics Menu.
  • Page 24 ELECTRICAL SYSTEM AND TESTING Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Monitor Menu – MAIN CONT (solenoid) Speed controller logic malfunction Disconnect the batteries and discharge does not indicate ON when the the controller. See Disconnecting The Failed controller FET (that powers up solenoid should be activated.
  • Page 25 ELECTRICAL SYSTEM AND TESTING Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Diagnostic Menu – FIELD MISSING Loose or disconnected motor field coil fault code wires at motor or speed controller or Repair and/or connect the field coil wires broken wire Failure of the motor field windings Section 16 –...

  • Page 26: Troubleshooting Guide 2

    ELECTRICAL SYSTEM AND TESTING Troubleshooting TROUBLESHOOTING GUIDE 2 TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Vehicle does not operate Batteries discharged Charge batteries Check vehicle wiring. See Wiring Improper or poor battery connections Diagrams beginning on page 11-2. Battery charger is connected to the Disconnect the battery charger from the vehicle –...
  • Page 27 ELECTRICAL SYSTEM AND TESTING Troubleshooting TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Vehicle runs slowly Test Procedure 14 – Motor Speed Sensor Speed sensor disconnected or failed on page 11-38 To change the programmed top speed of Incorrect speed setting the vehicle, an IQDM-P handset must be used Check vehicle wiring.

  • Page 28: Test Procedures

    ELECTRICAL SYSTEM AND TESTING Troubleshooting TEST PROCEDURES Using the following procedures, the entire IQ Plus electrical system can be tested without major disassembly of the vehicle. See following WARNING. ý WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured.
  • Page 29 ELECTRICAL SYSTEM AND TESTING Troubleshooting TEST PROCEDURE 1 – BATTERIES / VOLTAGE CHECK See General Warning, Section 10, Page 10-1. NOTE: The batteries must be properly maintained and fully charged in order to perform the following test procedures. Battery maintenance procedures, including watering information and allowable min- eral content, can be found in Section 14 of this manual.
  • Page 30 ELECTRICAL SYSTEM AND TESTING Troubleshooting TEST PROCEDURE 2 – ONBOARD COMPUTER SOLENOID LOCKOUT CIRCUIT See General Warning, Section 10, Page 10-1. The solenoid lockout circuit disables the vehicle when the battery charger is plugged into the vehicle. Use the following procedure to test the solenoid lockout circuit: 1.
  • Page 31 ELECTRICAL SYSTEM AND TESTING Troubleshooting Figure 11-8 Test Blue OBC Wire (+) Figure 11-9 Test Light Blue 18-Gauge Wire at 24-pin Connector (+) TEST PROCEDURE 3 – SOLENOID ACTIVATING COIL See General Warning, Section 10, Page 10-1. 1. Disconnect the batteries and discharge the controller. See Disconnecting The Batteries on page 10-3. 2.
  • Page 32 ELECTRICAL SYSTEM AND TESTING Troubleshooting TEST PROCEDURE 4 – MCOR VOLTAGE See General Warning, Section 10, Page 10-1. The accelerator position, which is proportional to the MCOR voltage, can be displayed with the IQDM hand- set. If an IQDM handset is not available, proceed to MCOR Voltage Test without the IQDM Handset on page 11-18.
  • Page 33 ELECTRICAL SYSTEM AND TESTING Troubleshooting 3. If reading is zero volts, check the purple/white wire continuity from the three-pin connector at the MCOR to the 24-pin connector at the speed controller. Check terminal positions in three-pin connector at the MCOR and the 24-pin connector. If all of the continuity readings are correct and the connectors are wired correctly, replace the speed controller.
  • Page 34 ELECTRICAL SYSTEM AND TESTING Troubleshooting page 10-3. 8.2. Disconnect the 24-pin connector at the speed controller. 8.3. Set a multimeter to 20k ohms. Connect the red (+) probe of the multimeter to the yellow wire at the MCOR three-pin connector with an insulation piercing probe. Connect black (–) probe to the purple/ white wire with an insulation-piercing probe.
  • Page 35 ELECTRICAL SYSTEM AND TESTING Troubleshooting TEST PROCEDURE 5 – A1 AND A2 MOTOR VOLTAGE See General Warning, Section 10, Page 10-1. 1. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands under the frame crossmember between the spring mount and side stringer, just forward of each rear wheel.
  • Page 36 ELECTRICAL SYSTEM AND TESTING Troubleshooting 6. With the IQDM still connected to the vehicle, place the Tow/Run Switch in the TOW position and wait 90 seconds. 7. If the IQDM display screen goes blank, the Tow/Run switch and connecting wires are operating correctly. 8.
  • Page 37 ELECTRICAL SYSTEM AND TESTING Troubleshooting TEST PROCEDURE 7 – CIRCUIT BREAKER See General Warning, Section 10, Page 10-1. 1. Place the key switch on the OFF position, the Tow/Run switch in the TOW position, and the Forward/ Reverse switch in the NEUTRAL position. 2.
  • Page 38 ELECTRICAL SYSTEM AND TESTING Troubleshooting NOTE: The key switch MUST function properly in order to test the MCOR limit switch with the IQDM hand- set. 5. Test the MCOR limit switch. 5.1. Select FOOT INPUT on the Monitor menu by using the SCROLL DISPLAY buttons on the IQDM. 5.2.
  • Page 39 ELECTRICAL SYSTEM AND TESTING Troubleshooting 5.4. If the voltage reading is zero volts when the accelerator pedal is pressed, check the key switch cir- cuit using the following test procedures. 5.4.1. Set a multimeter to 200 volts DC. Place black (–) probe on battery no. 8 negative post and the place red (+) probe (with insulation-piercing probe) on the blue wire where it connects to the MCOR.
  • Page 40 ELECTRICAL SYSTEM AND TESTING Troubleshooting SPEED CONTROLLER 24-PIN CONNECTOR WIRE TEST PROCEDURE Pin 1 – Tan (18-gauge) Test Procedure 10F – Pin 1 on page 11-33 Test Procedure 2 – Onboard Computer Solenoid Lockout Circuit Pin 2 – Light Blue (18-gauge) on page 11-16 Pin 3 –...
  • Page 41 ELECTRICAL SYSTEM AND TESTING Troubleshooting CAUT ION • Do not fully insert probes into the 24-pin plug. Doing so can result in a poor connection. 5. With the accelerator pedal fully up (not pressed), the multimeter should read approximately 1k ohms. 6.
  • Page 42 ELECTRICAL SYSTEM AND TESTING Troubleshooting Test Procedure 10B – Pin 2 See General Warning, Section 10, Page 10-1. Pin 2 in the 24-pin connector provides a connection point for the solenoid lockout circuit from the onboard computer to the speed controller. 1.
  • Page 43 ELECTRICAL SYSTEM AND TESTING Troubleshooting Detail: Front of 24-Pin Connector Figure 11-19 Test: Pin 2 (Light Blue Wire) 2008-2011 IQ Plus Electric Vehicle Maintenance and Service Supplement Page 11-29...
  • Page 44 ELECTRICAL SYSTEM AND TESTING Troubleshooting Test Procedure 10C – Pin 8 See General Warning, Section 10, Page 10-1. Pin 8 in the 24-pin connector provides a connection point for the MCOR limit switch to the speed controller. 1. Disconnect the batteries and discharge the controller. See Disconnecting The Batteries on page 10-3. 2.
  • Page 45 ELECTRICAL SYSTEM AND TESTING Troubleshooting 12. The multimeter should indicate zero volts when the accelerator pedal is not pressed. 13. If any other reading is obtained, check the following items: • Continuity of the wires in the wire harness • Onboard computer for proper operation. See Test Procedure 12 – Onboard Computer Gray Wire and Fuse on page 11-37.
  • Page 46 ELECTRICAL SYSTEM AND TESTING Troubleshooting Detail: Front of 24-Pin Connector Figure 11-21 Test: Pin 19 (Orange/White Wire) Test Procedure 10E – Pins 10 and 11 See General Warning, Section 10, Page 10-1. Pins 10 and 11 in the 24-pin connector provide a connection point for the Forward/Reverse rocker switch to the speed controller.
  • Page 47 ELECTRICAL SYSTEM AND TESTING Troubleshooting Test Procedure 10E – Pins 10 and 11, Continued: 8. Place the Forward/Reverse switch in the FORWARD position. The multimeter should indicate full battery voltage (approximately 48 volts). 9. Insert the red (+) probe of the multimeter into pin 11 (blue wire) of the 24-pin connector. Leave the black (–) probe (alligator clip) connected to the B–...
  • Page 48 ELECTRICAL SYSTEM AND TESTING Troubleshooting 2. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands under the frame crossmember between the spring mount and side stringer, just forward of each rear wheel.
  • Page 49 ELECTRICAL SYSTEM AND TESTING Troubleshooting Test Procedure 10G – Pin 17 See General Warning, Section 10, Page 10-1. Pin 17 in the 24-pin connector provides a connection point for the solenoid coil to the speed controller. The speed controller activates the solenoid coil by providing a ground to the solenoid coil at the appropriate time. 1.
  • Page 50 ELECTRICAL SYSTEM AND TESTING Troubleshooting Test Procedure 10J – Pin 23 1. Place the Tow/Run switch in the RUN position, the Forward/Reverse swith in the NEUTRAL position, and the key switch in the OFF position. 2. Set the multimeter for 200 volts DC. With an alligator clip, connect the red (+) probe of the multimeter to the positive terminal of battery # 1.
  • Page 51 ELECTRICAL SYSTEM AND TESTING Troubleshooting TEST PROCEDURE 12 – ONBOARD COMPUTER GRAY WIRE AND FUSE See General Warning, Section 10, Page 10-1. 1. With batteries connected and a multimeter set to 200 volts DC, connect the red (+) probe to the positive post of battery no.
  • Page 52 ELECTRICAL SYSTEM AND TESTING Troubleshooting Figure 11-27 Test 12: Charger Receptacle Red Wire TEST PROCEDURE 14 – MOTOR SPEED SENSOR See General Warning, Section 10, Page 10-1. Motor Speed Sensor Test with the IQDM Handset ý CAUT ION • 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 53 ELECTRICAL SYSTEM AND TESTING Troubleshooting Figure 11-28 Test 13: Speed Sensor Black/White Wire 4. Check voltage at the red motor speed sensor wire: 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.
  • Page 54 ELECTRICAL SYSTEM AND TESTING Troubleshooting troller if necessary. Figure 11-30 Test 13: Speed Sensor Light Green Wire 6. Reconnect the three-pin connector at the motor speed sensor. Using a multimeter set to 20 volts DC, place the black (–) probe on the battery no. 8 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 55 ELECTRICAL SYSTEM AND TESTING Troubleshooting TEST PROCEDURE 15 – SOLENOID CONTACTS See General Warning, Section 10, Page 10-1. 1. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands under the frame crossmember between the spring mount and side stringer, just forward of each rear wheel.
  • Page 56 ELECTRICAL SYSTEM AND TESTING Troubleshooting dash out slightly from under edge of cowl brace. 2.4. Pull center dash out from the frame and disconnect the wires from the electrical components mounted on the dash panel. Do not allow wires to touch. See following NOTE. NOTE: Take care to prevent key switch terminals and wires from touching the metal frame around the dash.
  • Page 57 ELECTRICAL SYSTEM AND TESTING Troubleshooting 6. Place the Forward/Reverse switch in REVERSE. Using a multimeter set to 200 volts DC, place the black (–) probe on the orange/white wire terminal end (that was disconnected from the reverse buzzer) and place the red (+) probe on battery no. 1 positive post. The reading should be approximately 48 volts (full battery voltage).
  • Page 58 ELECTRICAL SYSTEM AND TESTING Troubleshooting TEST PROCEDURE 20 – WALK AWAY BRAKING RELAY See General Warning, Section 10, Page 10-1. Walk Away Braking Relay Test with the IQDM Handset 1. Turn the key switch to the OFF position and place the Forward/Reverse switch in the NEUTRAL position. 2.

  • Page 59: Communication Display Module (Cdm)

    Last charge termination type (1 = Incomplete, 2 = DVDT, 4 = Normal, 8 = Max. timer). POWER Club Car PART #17075 Figure 11-32 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 vehicle.

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

    ELECTRICAL SYSTEM AND TESTING Troubleshooting 1 – Indicates the last charge cycle was incomplete and the batteries were not fully charged. Batteries should be charged again at the earliest opportunity. 2 – Indicates a back-up charge program was employed by the OBC to complete the charge cycle if a normal charge (4) is not possible.

  • 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 Failed Dash Light...

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

    SECTION 12 – IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS ý DANGER • See General Warning, Section 10, Page 10-1. ý WARNING • See General Warning, Section 10, Page 10-1. NOTE: For information secific to the IQDM-P handset programming features, see Section 18 – IQ DIS- PLAY MODULE (IQDM-P) Programming.

  • Page 64: Introductory Display

    IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Introductory Display INTRODUCTORY DISPLAY Immediately after the handset is connected to the vehicle, it begins loading the vehicle speed controller infor- mation. After a few seconds, the screen displays the following menu items: •...
  • Page 65 IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Menu Navigation DISPLAY SCREEN NAVIGATION BUTTON CHANGE VALUE BUTTON BOOKMARK BUTTONS Figure 12-2 Handset Controls Faults The faults menu displays all faults recorded by the speed controller since the history was last cleared. Each fault is listed only once in the fault history menu, even if the fault has occurred multiple times.

  • Page 66: Monitor Menu

    IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS 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 tech- nician to troubleshoot the vehicle by monitoring the handset as the key switch is cycled, Forward/Reverse switch is activated, etc.
  • 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 IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Monitor Menu Temp Cutback # Displays the number of times the TEMP CUTBACK fault has been detected. See Fault Descriptions on page 12-11. HPD # Displays the number of times the HPD fault has been detected. See Fault Descriptions on page 12-11. Main Welded # Displays the number of times the MAIN WELDED fault has been detected.
  • Page 69 IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Monitor Menu Relay Coil # Displays the number of times the RELAY COIL fault has been detected. See Fault Descriptions on page 12-11. Precharge # Displays the number of times the PRECHARGE fault has been detected. See Fault Descriptions on page 12-11.

  • Page 70: Faults Menu

    IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Faults Menu FAULTS MENU The faults menu is accessed by using the up or down arrow to scroll to faults and pressing the right arrow key to activate the menu. Faults displayed in the faults menu will aid the trained technician in troubleshooting the vehicle. Faults dis- played often indicate which components in the electrical system need to be tested.

  • Page 71: Fault Recovery

    IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Faults Menu 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: 1.
  • Page 72 IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Faults Menu CONTROLLER CONTROLLER TEST WHEN RECOVER WHEN RESPONSE FAULT 01 THROTTLE FAULT 1 Continuous Condition clears 02 UNDER VOLTAGE Continuous Condition clears 03 OVERVOLTAGE Continuous Condition clears 04 THERMAL CUTBACK Continuous Condition clears 06 HPD...

  • Page 73: Fault Descriptions

    IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Faults Menu FAULT DESCRIPTIONS The following faults can be detected by the IQ Plus 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 IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Faults Menu 30 Relay Coil Fault If the Walk Away relay develops an open circuit or is disconnected from the controller, a relay coil fault is detected. Main CONT DNC The main cont dnc (main contactor (solenoid) did not close) fault is detected when the speed controller has sent voltage to the solenoid activating coil but the solenoid contacts are not closed.

  • Page 76: Functions Menu

    IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Faults Menu FUNCTIONS MENU The functions menu is accessed by using the up or down arrow to scroll to functions and pressing the right arrow key to activate the menu. GET SETTINGS FROM CONTROLLER This function transfers all of the speed controller settings (except for “private speed mode”) from the vehicle speed controller to the handset.

  • Page 77: Write Settings To Controller

    IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Faults Menu All Controller Settings Saved in Programmer. Executing... OK (+) OK (+) Figure 12-3 Handset Executing Figure 12-4 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 78 IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Faults Menu 6. Select settings. 7. Select write settings to controller. 8. Press + on the change value button to confirm the operation. 9. The handset will display an “executing...” message for the next few seconds while the controller settings are being stored in the handset’s memory (Figure 12-3).

  • Page 79: Reset All Settings

    IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Information 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 80: Programmer Setup

    IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Programmer Setup PROGRAMMER SETUP The programmer setup menu selection allows the user to set the LCD display contrast, records the fault his- tory 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 81: Iqdm And Iqdm-P Handset Troubleshooting

    IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS IQDM and IQDM-P Handset Troubleshooting 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 IQDM and IQDM-P Series 2 handsets.

  • Page 82: Test Procedures

    IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Test Procedures TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Handset is “locked-up” – buttons do Disconnect the IQDM cord from the not respond Handset malfunction vehicle. Wait a few seconds and reconnect the handset to the vehicle Vehicle batteries –...
  • Page 83 IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Test Procedures The procedure for testing the handset cord adaptor is similar to the cord test. 1. 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 84 IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS Test Procedures set fails to function, See IQDM and IQDM-P Handset Troubleshooting on page 12-19. Figure 12-7 Testing IQDM Jack Test Procedure 3B – IQDM Jack (Speed Controller) See General Warning, Section 10, Page 10-1. 1.

  • Page 85: Section 13 - Electrical Components

    SECTION 13 – ELECTRICAL COMPONENTS ý DANGER • See General Warning, Section 10, Page 10-1. ý WARNING • See General Warning, Section 10, Page 10-1. KEY SWITCH See General Warning, Section 10, Page 10-1. Testing the Key Switch See Test Procedure 9, Section 11, Page 11-23. Key Switch Removal 1.
  • Page 86 ELECTRICAL COMPONENTS Key Switch 3. Slide center dash panel up steering column by snapping top out and then rotating the panel out and up. 4. Disconnect the wires from the key switch. Do not allow wires to touch. 5. From the back of the dash panel, push down on the retaining tabs surrounding the key switch (4) and remove the key switch cap (8).

  • Page 87: Forward/Reverse Rocker Switch

    ELECTRICAL COMPONENTS Forward/Reverse Rocker Switch FORWARD/REVERSE ROCKER SWITCH See General Warning, Section 10, Page 10-1. Testing the Forward/Reverse Rocker Switch See Test Procedure 16, Section 11, Page 11-41. Forward/Reverse Rocker Switch Removal 1. Disconnect the batteries and discharge the controller. See Disconnecting The Batteries on page 10-3. 2.

  • Page 88: Tow/Run Switch

    ELECTRICAL COMPONENTS Tow/Run Switch Figure 13-3 Tow/Run Switch and Forward/Reverse Rocker Switch TOW/RUN SWITCH See General Warning, Section 10, Page 10-1. Testing the Tow/Run Switch See Test Procedure 6, Section 11, Page 11-21. Tow/Run Switch Removal 1. Disconnect the batteries and discharge the controller. See Disconnecting The Batteries on page 10-3. 2.

  • Page 89: Circuit Breaker

    ELECTRICAL COMPONENTS Circuit Breaker CIRCUIT BREAKER See General Warning, Section 10, Page 10-1. Testing the Circuit Breaker See Test Procedure 7, Section 11, Page 11-23. Circuit Breaker Removal 1. Disconnect the batteries and discharge the controller. See Disconnecting The Batteries on page 10-3. 2.

  • Page 90: Motor Controller Output Regulator (Mcor)

    ELECTRICAL COMPONENTS Motor Controller Output Regulator (MCOR) MOTOR CONTROLLER OUTPUT REGULATOR (MCOR) See General Warning, Section 10, Page 10-1. Testing the MCOR See Section 11, Test Procedure 4, Page 11-18 and Test Procedure 9, Page 11-23. MCOR Removal 1. Disconnect the batteries and discharge the controller. See Disconnecting The Batteries on page 10-3. 2.

  • Page 91: Reverse Buzzer

    ELECTRICAL COMPONENTS Reverse Buzzer MCOR Installation 1. Insert the splined end of the drive bar (4) through the hole in the passenger-side frame I-beam as shown (Figure 13-5, Page 13-6). 2. Position the opposite end of the drive bar so that the accelerator pedal sits between the two pins. 3.

  • Page 92: Solenoid

    ELECTRICAL COMPONENTS Solenoid Installing the Speed Controller Cover 1. Place the curved edges on the bottom of the speed controller cover (2) into the slots on the component mounting plate. 2. Press the speed controller cover onto the component mounting plate over the speed controller and other electrical components.
  • Page 93 ELECTRICAL COMPONENTS Solenoid 5. Lift the solenoid (2) up and off of the component mounting plate. SOLENOID TYPICAL 2 PLACES Figure 13-7 Solenoid Solenoid Installation 1. Mount solenoid (2) onto component mounting plate with screws (1) (Figure 13-7, Page 13-9). 2.

  • Page 94: Onboard Computer (Obc)

    ELECTRICAL COMPONENTS Solenoid ONBOARD COMPUTER (OBC) See General Warning, Section 10, Page 10-1. Testing the Onboard Computer See Section 11, Test Procedure 2, Page 11-16, Test Procedure 11, Page 11-36, and Test Procedure 12, Page 11-37. Onboard Computer Removal 1. Disconnect the batteries and discharge the controller. See Disconnecting The Batteries on page 10-3. 2.

  • Page 95: Solid State Speed Controller

    ELECTRICAL COMPONENTS Solid State Speed Controller 3. Connect the gray wire to the OBC. 4. Connect the black 6-gauge wire and black 10-gauge wire to the speed controller B– terminal with the washer and bolt and tighten to 9 ft-lb (12.2 N·m) (Figure 13-8, Page 13-10). 5.
  • Page 96 ELECTRICAL COMPONENTS Solid State Speed Controller Speed Controller Installation 1. Install the four bolts (1) that hold the speed controller (2) to the component mounting plate and tighten to 60 in-lb (6.8 N·m) (Figure 13-9, Page 13-11). 2. Using the wiring diagram, install the multi-pin connectors and all wires as illustrated. See Wiring Dia- grams, Section 11, Page 11-2.

  • Page 97: Charger Receptacle

    ELECTRICAL COMPONENTS Charger Receptacle CHARGER RECEPTACLE See General Warning, Section 10, Page 10-1. 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 98: 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 13-14).

  • Page 99: Battery Warning Light

    ELECTRICAL COMPONENTS Battery Warning Light 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 (CC P/N 1014305) to minimize corrosion. BATTERY WARNING LIGHT See General Warning, Section 10, Page 10-1.
  • Page 100 ELECTRICAL COMPONENTS Ferrite Beads – CE Mark vehicles To remove either type of ferrite bead, cut the wire tie and release the two tabs on the side of the ferrite bead to open and remove from wire or wires. To install either type of ferrite bead, release the two tabs on the side of the ferrite bead to open and place onto wire or wires.
  • Page 101 ELECTRICAL COMPONENTS Ferrite Beads – CE Mark vehicles Ferrite Beads – Villager 8 IQ Plus Vehicle NOTE: If a Villager 8 being serviced or repaired is found to have beads in an arrangement other than what is shown in this manual, relocate the beads to these updated locations. To remove either type of ferrite bead, cut the wire tie and release the two tabs on the side of the ferrite bead to open and remove from wire or wires.

  • Page 103: 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 104: Battery Replacement

    BATTERIES Battery Replacement BATTERY REPLACEMENT See General Warning, Section 10, Page 10-1. ý WARNING • To prevent electrolyte leakage from the battery vents, batteries must be kept in an upright position. Tipping a battery beyond a 45° angle in any direction can allow a small amount of electrolyte to leak out the vent hole.
  • Page 105 BATTERIES Battery Replacement (–) Figure 14-3 Battery Configuration (Turf 2, Carryall 2, Carryall 6 (Style B)) (Viewed from driver side of vehicle) 1. Place TOW/RUN Switch in TOW before disconnecting or connecting battery cables. 2. Remove negative battery cable. 3. Remove positive battery cable. Connect battery cables in reverse order.

  • Page 106: Battery Care

    BATTERIES Battery Care BATTERY CARE See General Warning, Section 10, Page 10-1. ý WARNING • Ensure battery connections are clean and properly tightened. • Use only 4-gauge (AWG) wires with low-resistance terminals to replace battery wires on IQ Plus models. •...

  • Page 107: Water Quality

    This process creates a finished product free of minerals, having left all the impu- rities in the original water sample. Club Car, along with our battery manufacturers, highly recommends that distilled water be used in electric vehicle batteries.
  • Page 108 If using tap water, Club Car's Service Parts Department offers two different deionizer systems: one for vehi- cles equipped with the Single Point Water System (SPWS) P/N AM1240701 and the other for vehicles without SPWS, P/N AM10974.

  • Page 109: Battery Charging

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

  • Page 110: Incoming Ac Service

    See following NOTE. NOTE: When vehicles are being rotated, the Club Car CDM (Communication Display Module) can be a very helpful service tool. Monitoring the value of function 3 with the CDM simplifies vehicle usage scheduling.

  • Page 111: Battery Troubleshooting Chart

    BATTERIES Battery Troubleshooting Chart BATTERY TROUBLESHOOTING CHART Vehicle not operating to expectation. Fully Charge Batteries. Battery Charger Test Reading of 6 amps or more. Reading below 6 amps and on-charge voltage above 56 volts. Check electrical system and charger for problems. SeeTroubleshooting Guide On-Charge Voltage Test If problem is not found, go to...

  • Page 112: Battery Testing

    BATTERIES Battery Testing BATTERY TESTING See General Warning, Section 10, Page 10-1. Four tests have been developed to help diagnose problems with batteries that have not performed as expected. Because each test becomes progressively more detailed and time-consuming, begin with the first test and follow through with the other tests until the problem has been identified as outlined in the Battery Troubleshooting Chart (Figure 14-5, Page 14-9).
  • Page 113 BATTERIES Battery Testing 3. Squeeze the rubber bulb of the hydrometer and insert into the cell. Slowly release the bulb, drawing elec- trolyte up into the glass tube of the hydrometer. 4. When the float rises off the bottom, adjust the electrolyte level so that the float rides free of the bottom but does not strike the top of the glass tube.

  • Page 114: Discharge Test

    BATTERIES Battery Testing 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.
  • Page 115 BATTERIES Battery Testing Interpreting Discharge Test Results 1. If discharge time is 60 minutes or higher, the problem is not with the batteries. 2. If discharge times are low (less than 60 minutes), replace batteries below 5.0 volts. BATTERY VOLTAGES BATTERY CONDITION 5.25 V 5.25 V...

  • Page 116: Battery Troubleshooting Examples

    BATTERIES Battery Testing BATTERY TROUBLESHOOTING EXAMPLES The following information represents a few examples of troubleshooting battery problems. Example 1 Vehicle no. 68 was suspected of having a bad battery due to its performance. As a result, the battery charger test was performed. After a full charge, the battery charger ammeter read 8.0 amps. Next, the on-charge volt- age test was performed and the following results were recorded: BATTERY NO.

  • Page 117: 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 119: Section 15 - Battery Charger

    SECTION 15 – BATTERY CHARGER Refer to the appropriate battery charger maintenance and service manual. 2008-2011 IQ Plus Electric Vehicle Maintenance and Service Supplement Page 15-1...

  • Page 121: Section 16 - Motor (Model Da5-4006)

    The IQ Plus vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. This 3.7 horse- power motor is designed for use on IQ Plus vehicles only. Club Car recommends that motors requiring major repair be sent to a qualified motor repair shop; however, there are many relatively simple tasks that can be performed by a technician with general knowledge and experience in electric motor repair.

  • Page 122: Motor

    MOTOR (MODEL DA5-4006) Motor 2. Disconnect wires from the A1 and A2 terminals on the motor using two wrenches to prevent posts from turning. Set a multimeter to 200 ohms and place the red (+) probe on the A1 terminal and black (–) probe on the A2 terminal.
  • Page 123 MOTOR (MODEL DA5-4006) Motor Figure 16-1 Lift Vehicle with Floor Jack Figure 16-2 Vehicle Supported on Jack Stands 5. Remove both rear wheels. 6. Remove the nut, cup washer, and bushing from the bottom side of the shock absorber. Compress the shock absorber (pushing upwards) to move it out of the way (Figure 16-3, Page 16-3).

  • Page 124: Motor Disassembly

    MOTOR (MODEL DA5-4006) Motor Figure 16-4 Speed Sensor Magnet Figure 16-5 End Cap Removal MOTOR DISASSEMBLY 1. Release the clasp and remove the headband assembly (21) from the motor. Visually inspect brushes and springs. (Figure 16-13, Page 16-10). 2. Before continuing disassembly, place match marks on the motor end cap (20) and motor frame (14). 3.
  • Page 125 MOTOR (MODEL DA5-4006) Motor housing when removing bolts. 6. Remove the end cap and armature from the motor frame (Figure 16-5, Page 16-4). 7. Inspect the brush springs for proper tension. See Motor Brush, Spring, and Terminal Insulator Inspection on page 16-7. 8.

  • Page 126: Motor Component Testing And Inspection

    MOTOR (MODEL DA5-4006) Motor Component Testing and Inspection Figure 16-8 Brush Rigging Removal Figure 16-9 Retaining Ring Removal MOTOR COMPONENT TESTING AND INSPECTION See General Warning, Section 10, Page 10-1. ARMATURE INSPECTION AND TESTING 1. Remove the motor from the vehicle. See Motor Removal, Section 16, Page 16-2. 2.

  • Page 127: Motor Frame And Field Windings Inspection

    MOTOR (MODEL DA5-4006) Motor Component Testing and Inspection Armature Ground Test CAUT ION • Do not submerge the armature in solvent. NOTE: Before testing the armature, wipe it clean with a clean cloth. Remove any carbon dust and metal particles from between the commutator bars. 1.
  • Page 128 MOTOR (MODEL DA5-4006) Motor Component Testing and Inspection 4.1. Place a C-shaped steel plate on a scale. 4.2. Place the end of the C-shaped plate so that it is between the spring and the brush. 4.3. Gently pull the scale to obtain the spring tension reading. See following CAUTION. CAUT ION •...
  • Page 129 MOTOR (MODEL DA5-4006) Motor Component Testing and Inspection Terminal Insulator Inspection 1. Remove the motor from the vehicle. See Motor Removal, Section 16, Page 16-2. 2. Remove the terminal insulators by performing steps 1 through 11 of Motor Disassembly on page 16-4. 1.
  • Page 130 MOTOR (MODEL DA5-4006) Motor Component Testing and Inspection MOTOR MOUNTING TYPICAL 3 PLACES Figure 16-13 Motor Page 16-10 2008-2011 IQ Plus Electric Vehicle Maintenance and Service Supplement...

  • Page 131: Reconditioning The Motor

    MOTOR (MODEL DA5-4006) Reconditioning the Motor RECONDITIONING THE MOTOR See General Warning, Section 10, Page 10-1. Motor reconditioning must be performed by a qualified motor repair technician. The use of proper tools and procedures is absolutely essential for successful motor reconditioning. Motor Specifications Any rework must be performed by a qualified technician.

  • Page 132: Motor Installation

    MOTOR (MODEL DA5-4006) Motor Installation Figure 16-14 Retracted Brushes Figure 16-15 Armature Installation 2.5. One at a time, push the brushes back until they are completely retracted into their mounting slots (Figure 16-14, Page 16-12). 3. With the brushes retracted, use an arbor press to press the armature shaft into the end cap bearing (Figure 16-15, Page 16-12).
  • Page 133 MOTOR (MODEL DA5-4006) Motor Installation shaft) (Figure 16-17, Page 16-13). 2.4. The grease should be evenly distributed in the grooves to a width of approximately 3/8 inch (9.5 mm). 2.5. Use a flat screwdriver to clean the grease out of one of the grooves and allow air to escape when the motor is pushed onto the input shaft.
  • Page 134 MOTOR (MODEL DA5-4006) Motor Installation 1/16 INCH (1.6 MM) CHAMFER SHAFT END Figure 16-18 Clean Chamfer and Input Shaft End Figure 16-19 Gap at Motor and Transaxle 3.2. Loosely install the four bolts that secure the motor to the transaxle. Do not tighten. 3.3.
  • Page 135 MOTOR (MODEL DA5-4006) Motor Installation 9. Place the Tow/Run switch in the TOW position and connect the batteries, positive (+) cable first. Tighten battery terminals to 110 in-lb (12.4 N·m) and coat terminals with Battery Terminal Protector Spray (CC P/ N 1014305) to minimize corrosion.

  • Page 137: Section 17 - Transaxle (Type G)

    SECTION 17 – TRANSAXLE (TYPE G) ý DANGER • See General Warning, Section 10, Page 10-1. ý WARNING • See General Warning, Section 10, Page 10-1. LUBRICATION See General Warning, Section 10, Page 10-1. There are two plugs located on the lower half of the transaxle housing. The upper plug (21) (as viewed when the vehicle is on a level surface) is used as a lubricant level indicator (Figure 17-5, Page 17-3).
  • Page 138 TRANSAXLE (TYPE G) Axle Bearing and Shaft Axle Shaft and Oil Seal Removal, Continued: NOTE: Do not discard the adapter ring. If the adapter ring is lost or damaged, the axle tube will have to be replaced. 6.2. Use a press to separate the axle oil seal (15) from the adapter ring (39) (Figure 17-3, Page 17-2). Retain the adapter ring and discard the oil seal.
  • Page 139 TRANSAXLE (TYPE G) Axle Bearing and Shaft REFERENCE MOTOR 000223-002 Figure 17-5 Transaxle – Type G 2008-2011 IQ Plus Electric Vehicle Maintenance and Service Supplement Page 17-3...

  • Page 140: Axle Bearing

    TRANSAXLE (TYPE G) Axle Bearing and Shaft Axle Shaft and Oil Seal Installation 1. If previously removed, install a new oil seal. 1.1. Clean seal seat in the adapter ring (39) (Figure 17-3, Page 17-2). 1.2. Place a new seal (15) in the adapter ring with the seal lip facing toward the adapter ring lip (Figure 17-3, Page 17-2).

  • Page 141: Transaxle

    TRANSAXLE (TYPE G) Transaxle TRANSAXLE See General Warning, Section 10, Page 10-1. TRANSAXLE REMOVAL 1. Place chocks at the front wheels and slightly loosen lug nuts on both rear wheels. 2. Place a floor jack under the transaxle and raise the rear of the vehicle. Position jack stands under the frame crossmember between the spring mount and the side stringer, just forward of each rear wheel.
  • Page 142 TRANSAXLE (TYPE G) Transaxle Transaxle Removal, Continued: 5. Disconnect the shock absorbers from their lower mounts (Figure 17-8, Page 17-5). 6. Disconnect the four motor wires. Use two wrenches to prevent the post from turning. 7. With a floor jack supporting the transaxle, remove lower spring shackle nuts and bolts. Position shackles so they are clear of springs (Figure 17-9, Page 17-5).

  • Page 143: Transaxle Disassembly, Inspection, And Assembly

    TRANSAXLE (TYPE G) Transaxle Disassembly, Inspection, and Assembly APPEARANCE OF MOTOR MAY BE DIFFERENT FROM THE MOTOR SHOWN ABOVE. Figure 17-12 Motor Positioning Bolt TRANSAXLE DISASSEMBLY, INSPECTION, AND ASSEMBLY See General Warning, Section 10, Page 10-1. TRANSAXLE DISASSEMBLY AND INSPECTION 1.
  • Page 144 TRANSAXLE (TYPE G) Transaxle Disassembly, Inspection, and Assembly Transaxle Disassembly and Inspection, Continued: 7. Press the bearing (18) off the intermediate gear assembly (Figure 17-5, Page 17-3). PRESS RAM ARBOR Figure 17-13 Intermediate Gear Assembly 8. Disassemble the differential gear case: 8.1.

  • Page 145: Transaxle Assembly

    TRANSAXLE (TYPE G) Transaxle Disassembly, Inspection, and Assembly DIFFERENTIAL GEAR DIFFERENTIAL LEFT DIFFERENTIAL GEAR CASE Figure 17-15 Differential Pin Figure 17-16 Left Differential 8.6. Remove the differential gears and thrust plates (3 and 4). 8.7. Inspect the bearings (13) of the differential case (26) and replace them if they are damaged (Figure 17-5, Page 17-3).

  • Page 146: Transaxle Installation

    TRANSAXLE (TYPE G) Transaxle Installation Transaxle Assembly, Continued: 7. Install both dowel pins (25) in the transaxle housing (20) (Figure 17-5, Page 17-3). 8. Install left half of transaxle housing: 8.1. Place a 1/8-inch (3 mm) bead of Three Bond liquid gasket on mating surface of housing. 8.2.
  • Page 147 TRANSAXLE (TYPE G) Transaxle Installation 3. Install the two U-bolts, jounce bumper mount (if required), and spacers, lockwashers, and nuts. Tighten the nuts to 25 ft-lb (34 N·m). Tighten the U-bolt nuts so an equal amount of thread is visible on each leg of the bolt.

  • Page 149: Section 18 - Iq Display Module (Iqdm-P) Series 2 Programming

    SECTION 18 – IQ DISPLAY MODULE (IQDM-P) SERIES 2 PROGRAMMING ý DANGER • See General Warning, Section 10, Page 10-1. ý WARNING • See General Warning, Section 10, Page 10-1. NOTE: For information pertaining to the introductory display, menu navigation, and monitor, faults and fun- tion menus, See Section 12 - IQ DISPLAY MODULE (IQDM) and IQDM-P Diagnostics.

  • Page 150: 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 151: M1/M2 Fast Accel

    IQ DISPLAY MODULE (IQDM-P) SERIES 2 PROGRAMMING Plugging the Handset into the Vehicle M1/M2 FAST ACCEL M1/M2 fast accel (fast acceleration) is an option that can be enabled or disabled. With fast accel turned on, the vehicle will accelerate at a noticeably faster rate. With this feature turned off, the vehicle speed will grad- ually increase, even if the accelerator is quickly pressed to the floor.

  • Page 152: M1/M2 Speed Cal

    IQ DISPLAY MODULE (IQDM-P) SERIES 2 PROGRAMMING Plugging the Handset into the Vehicle M1/M2 SPEED CAL The M1/M2 speed cal (speed calibration) menu item allows the user to fine tune the vehicle speed. This fea- ture cannot be used to increase the vehicle speed. The range for speed calibration is 0 to 30. Each time the number is increased, the top speed will be decreased by approximately 0.1 mph (0.2 km/h).

  • Page 153: 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 155 INDEX charger receptacle armature, motor fuse link ............13-14 see motor, armature installation ..........13-14 removal ............13-14 installation ............13-13 batteries ...............14-1 removal ............13-13 see also battery charger testing ............11-37 care ..............14-4 circuit breaker installation .........13-5 charging ............14-7 circuit breaker removal ........13-5 deep discharge ..........14-7 circuit breaker testing ........11-23 communication display module (CDM) electrolyte...
  • Page 156 INDEX menu navigation ..........12-2 speed sensor magnet program menu ..........18-2 inspection ............ 16-9 test procedures ..........12-20 testing ............11-21 troubleshooting ..........12-19 see test procedures, motor IQDM General Info ..........12-1 zero speed detect ..........11-1 IQDM-P ..............18-1 motor braking see regenerative braking motor controller output regulator (MCOR)
  • Page 157 INDEX troubleshooting IQDM ........12-19 test procedures 1 – batteries/voltage check ......11-15 water level 2 – onboard computer solenoid lockout circuit 11-16 see batteries, electrolyte level 3 – solenoid activating coil ......11-17 4 – MCOR ............11-18 5 – motor, A1 and A2 voltage ......11-21 zero speed detect ..........11-1 6 –...
  • Page 159 5. If you are reviewing a Kit Instruction, were all indicated parts included in your kit? Yes / No Your Comments and Suggestions: Please send a copy of this page to: Fax: (706) 228-2662 or Thank You! E-mail: Tech_Pubs@clubcar.com Club Car’s Technical Publications Department 2008-2011 IQ Plus Electric Vehicle Maintenance and Service Supplement...
  • Page 161 Club Car NOTES...
  • Page 162 Club Car NOTES...
  • Page 164 Club Car, LLC www.clubcar.com P.O. Box 204658 Phone 1.706.863.3000 Augusta, GA 30917-4658 1.800.ClubCar Int’l +1 706.863.3000 1.706.863.5808...

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