Club Car Electric Precedent 2008 Maintenance And Service Manual
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Club Car Electric Precedent 2008 Maintenance And Service Manual

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2008 Electric Precedent
Maintenance and
Service Manual
IQ System and Excel System Vehicles
Manual Number 103373101
Edition Code 0907D0309C

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Summary of Contents for Club Car Electric Precedent 2008

  • Page 1 2008 Electric Precedent Maintenance and Service Manual IQ System and Excel System Vehicles Manual Number 103373101 Edition Code 0907D0309C...
  • Page 3 Club Car distributor/dealer representative or by a Club Car factory-trained technician. It is the policy of Club Car, Inc. to assist its distributors and dealers in continually updating their service knowledge and facilities so they can provide prompt and efficient service for vehicle owners. Regional technical representatives, 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 5: Table Of Contents

    CONTENTS SECTION 1 — SAFETY ............................. 1-1 General Warnings............................1-1 SECTION 2 — VEHICLE SPECIFICATIONS ....................... 2-1 SECTION 3 — GENERAL INFORMATION......................3-1 Serial Number Identification..........................3-1 Safety Committee ............................3-2 Storage................................. 3-2 Preparing the Electric Vehicle for Extended Off-Season Storage..............3-3 Returning the Stored Electric Vehicle to Service ..................
  • Page 6 Debris Shields ............................5-3 Brake Return Spring ..........................5-3 Pawl Assembly ............................5-3 Accelerator Return Spring .......................... 5-4 Pedal Group Installation ..........................5-6 SECTION 6 — WHEEL BRAKE ASSEMBLIES....................6-1 General Information ............................6-1 Brake Shoe Removal ............................. 6-1 Brake Assembly Cleaning ..........................6-5 Brake Shoe Installation ..........................
  • Page 7 SECTION 9 — REAR SUSPENSION........................9-1 General Information ............................9-1 Shock Absorbers ............................9-1 Shock Absorber Removal and Inspection ....................9-1 Shock Absorber Installation ........................9-1 Leaf Springs (Two-Passenger Vehicles) ......................9-2 Leaf Spring Removal (Two-Passenger Vehicles)..................9-2 Leaf Spring Installation (Two-Passenger Vehicles) ..................9-3 Leaf Springs (Four-Passenger Vehicles) ......................
  • Page 8 Field PWM .............................. 13-5 Speed Pulses ............................13-5 Foot Input ............................... 13-5 Forward Input ............................13-6 Reverse Input............................13-6 Main Cont ............................... 13-6 Key Input ..............................13-6 Password Tries (IQDM-P only) ......................... 13-6 10.3 Transaxle............................13-6 20+ Speed .............................. 13-6 Faults Menu ..............................
  • Page 9 Batt Aux Voltage ............................14-5 Temperature............................14-5 Arm Current ............................14-5 Field Current ............................14-5 Armature PWM............................14-5 Field PWM .............................. 14-5 Brake Volts In ............................14-5 Speed Pulses ............................14-6 Foot Input ............................... 14-6 Key Input ..............................14-6 Forward Input ............................14-6 Reverse Input............................
  • Page 10 Battery Warning Light Removal ........................ 15-2 Battery Warning Light Installation......................15-3 Forward/Reverse Rocker Switch........................15-3 Testing the Forward/Reverse Rocker Switch....................15-3 Forward/Reverse Rocker Switch Removal....................15-3 Forward/Reverse Rocker Switch Installation ....................15-4 Electronics Module Cover – Style A Battery Configuration ................15-5 Electronics Module Cover Removal ......................
  • Page 11 Aiming the Headlight Beam ........................15-25 Ferrite Beads – CE Mark Vehicles .......................15-26 SECTION 16 — BATTERIES..........................16-1 General Information ............................. 16-1 Battery Troubleshooting Chart ........................16-2 Battery Testing – 12 Volt..........................16-3 Battery Charger Test ..........................16-3 On-Charge Voltage Test ........................... 16-3 Hydrometer Test ............................
  • Page 12 Motor Assembly............................18-10 Motor Installation ............................18-12 Motor Speed Sensor ...........................18-16 Testing the Motor Speed Sensor ......................18-16 Motor Speed Sensor Removal .........................18-16 Motor Speed Sensor Installation ......................18-16 SECTION 19 — MOTOR (MODEL EJ4-4001) ....................19-1 General Information ............................. 19-1 Motor Identification ............................19-1 External Motor Testing ..........................
  • Page 13 2008 Electric Precedent Maintenance and Service Manual Page xi...

  • Page 15: Section 1 - Safety

    SECTION 1 — SAFETY To ensure the safety of those servicing Club Car vehicles, and to protect the vehicles from possible damage resulting from improper service or maintenance, the procedures in this manual must be followed. It is important to note that throughout this manual there are statements labeled DANGER, WARNING, or CAUTION.
  • Page 16 General Warnings SAFETY WARNING • Only trained technicians should service or repair the vehicle or battery charger. Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair. The appropriate instructions must be used when performing maintenance, service, or accessory installation.
  • Page 17 SAFETY General Warnings (–) (–) (Viewed from driver side of vehicle) (Viewed from driver side of vehicle) 1. Place TOW/RUN Switch in TOW before disconnecting or connecting 1. Place TOW/RUN Switch in TOW before disconnecting or connecting battery cables. battery cables. 2.

  • Page 19: Section 2 - Vehicle Specifications

    SECTION 2 — VEHICLE SPECIFICATIONS TWO-PAS- FOUR-PAS- SENGER SENGER SPECIFICATIONS ELECTRIC ELECTRIC VEHICLE VEHICLE POWER SOURCE Drive motor: Direct drive, 48 volts DC, shunt-wound, 3.2 hp • • Transaxle: Double reduction helical gear with 12.3:1 direct drive axle • • Electrical system: 48 volts DC, reduced speed reverse •...
  • Page 20 General Warnings VEHICLE SPECIFICATIONS TWO-PAS- FOUR-PAS- SENGER SENGER SPECIFICATIONS ELECTRIC ELECTRIC VEHICLE VEHICLE 17 ft - 4in. 17 ft - 4 in. Curb clearance circle (diameter) (528 cm) (528 cm) Standard seating capacity LIQUID CAPACITIES 22 oz. (.67 22 oz. (.67 Transaxle liters) liters)

  • Page 21: Section 3 - General Information

    • See General Warnings on page 1-1. Important features unique to the different models covered in this manual are highlighted. Club Car, Inc. recommends the owner/operator read and understand this manual and pay special attention to features specific to their vehicle(s).

  • Page 22: Safety Committee

    • Where golf cars should be driven. • Ensuring that proper warnings of driving hazards are displayed and visible. See below for list of signs available from Club Car Service Parts Department. • Who should and who should not drive golf cars.

  • Page 23: Preparing The Electric Vehicle For Extended Off-Season Storage

    GENERAL INFORMATION Storage CAUTION • Batteries in low state of charge will freeze at low temperatures. • To avoid exposing electrical components to moisture and subsequent damages, do not use any type of pressure washing or steam cleaning equipment to wash the vehicle. •...

  • Page 25: Section 4 - Body And Trim

    A garden hose at normal residential water pressure is adequate. Club Car does not recommend any type of pressure washing or steam cleaning. Such a process (especially if the vehicle has a Surlyn rear body that is removed) will expose electrical components to moisture. Moisture entering electrical components can result in water damage and subsequent component failure.

  • Page 26: Front And Rear Body Repair

    Front and Rear Body Repair BODY AND TRIM Difficult Stains: Dampen a soft, white cloth with a solution of 10% household bleach (sodium hypochlorite) and 90% water. Rub gently to remove stain, then rinse with a water dampened cloth to remove bleach concentration. More Difficult Stains: Perform previous procedure using full-strength bleach, or allow bleach to puddle on affected area for approximately 30 minutes.

  • Page 27: Gouges, Punctures, Tears, Large Scratches, And Abrasions

    BODY AND TRIM Front Body Thoroughly clean the affected area using a strong, non-abrasive detergent and hot water, then clean with Ultra-Kleen ® Solvent Cleaner to remove any oil-based contaminants. Lightly buff imperfection with a clean soft cloth or buff pad. Do not use any kind of rubbing (abrasive) compound on body assemblies.
  • Page 28 Front Body BODY AND TRIM Figure 4-1 Front Body Page 4-4 2008 Electric Precedent Maintenance and Service Manual...

  • Page 29: Front Bumper

    BODY AND TRIM Front Bumper FRONT BUMPER The underbody bracket (1) connects the front suspension to the front underbody (Figure 4-2, Page 4-5). Each bracket is secured in place by two taptite screws (2) tightened to 13 ft-lb (17.6 N·m). The front bumper (3) is attached to the vehicle frame rails by nuts (5) and bolts (4).

  • Page 30: Instrument Panel Installation - Early Model Year

    Instrument Panel BODY AND TRIM INSTRUMENT PANEL INSTALLATION – EARLY MODEL YEAR Position dash assembly (1) on vehicle. Make sure tabs on the forward edge engage to front underbody. Secure assembly in place with three screws (2) (Figure 4-3, Page 4-6). Tighten screws to 8.8 ft-lb (12 N·m). Position dash tray (6) in dash and secure with two barrel fasteners (7).

  • Page 31: Instrument Panel Installation - Late Model Year

    BODY AND TRIM Instrument Panel INSTRUMENT PANEL INSTALLATION – LATE MODEL YEAR Position dash assembly (4) on vehicle. Make sure tabs on the forward edge engage to front underbody. Secure assembly in place with two screws (5) and plastic rivet (6) (Figure 4-4, Page 4-7). Tighten screws to 8.8 ft-lb (12 N·m).

  • Page 32: Floor Mat And Retainers

    Floor Mat and Retainers BODY AND TRIM FLOOR MAT AND RETAINERS See General Warnings on page 1-1. The floor mat retainers secure the floor mat to the vehicle and also provide a clean appearance to the side of the vehicle. Normally, if only the floor mat (3) needs to be removed, the screws (2) must be removed to allow the floor mat to be slid from beneath the retainers (1) (Figure 4-5, Page 4-8).

  • Page 33: Kick Plate And Charger Receptacle Bezel

    BODY AND TRIM Kick Plate and Charger Receptacle Bezel KICK PLATE AND CHARGER RECEPTACLE BEZEL See General Warnings on page 1-1. KICK PLATE AND CHARGER RECEPTACLE BEZEL REMOVAL If charger bezel (4) requires removal, use charger bezel tool (CCI P/N 102562401) to remove bezel from the kick plate (Figure 4-6, Page 4-9).

  • Page 34: Rear Body - Two-Passenger Vehicles

    Rear Body – Two-Passenger Vehicles BODY AND TRIM REAR BODY – TWO-PASSENGER VEHICLES See General Warnings on page 1-1. UNIVERSAL ACCESSORY MOUNTING The Structural Accessory Module (SAM) includes two threaded inserts on both the driver side and the passenger side (Figure 4-7, Page 4-10).

  • Page 35: Rear Body Components (Two-Passenger)

    BODY AND TRIM Rear Body – Two-Passenger Vehicles Sweater Basket The sweater basket (11) is secured to the bag hoop assembly by three screws (12). Tabs on the upper edge of the basket align with holes in the bag hoop (6) for installation purposes. Tighten screws (12) to 4.8 ft-lb (6.5 N·m) to secure the sweater basket (Figure 4-8, Page 4-12).
  • Page 36 Rear Body – Two-Passenger Vehicles BODY AND TRIM Figure 4-8 Backrest and SAM Page 4-12 2008 Electric Precedent Maintenance and Service Manual...
  • Page 37 BODY AND TRIM Rear Body – Two-Passenger Vehicles * Two-Passenger Vehicles Only Figure 4-9 Rear Body Components 2008 Electric Precedent Maintenance and Service Manual Page 4-13...

  • Page 38: Rear Body - Four-Passenger Vehicles

    Rear Body – Four-Passenger Vehicles BODY AND TRIM REAR BODY – FOUR-PASSENGER VEHICLES See General Warnings on page 1-1. SEAT BACKS Seat Back Removal Remove screws (9 or 13) securing seat back (8 or 11) to seat support and remove the seat back (Figure 4-10, Page 4-14).

  • Page 39: Foot Deck

    BODY AND TRIM Rear Body – Four-Passenger Vehicles Seat Support Installation Install in the reverse order of removal. Tighten bolts (4) to 53 in-lb (6 N·m). Tighten screws (5) to 44 in-lb (5 N·m). Tighten bolts (8 and 11) to 124 in-lb (14 N·m) (Figure 4-11, Page 4-15).

  • Page 40: Rear Body Components (Four-Passenger)

    Rear Body – Four-Passenger Vehicles BODY AND TRIM Figure 4-12 Foot Deck (Four-Passenger Vehicles) REAR BODY COMPONENTS (FOUR-PASSENGER) Rear Beauty Panel Removal Remove seat support. See Seat Support Removal on page 4-14. Remove four screws (13) attaching the rear beauty panel (12) to the fuel bucket (Figure 4-9, Page 4-13). Remove two screws (14) and remove the Forward/Reverse switch housing (15) from vehicle.

  • Page 41: Canopy - Two-Passenger

    BODY AND TRIM Canopy – Two-Passenger Lift the rear edge of the rear underbody (4) until the front portion slides out from beneath the front underbody. Remove the rear underbody from the vehicle. Rear Underbody Installation Install rear underbody (4) on the vehicle (Figure 4-9, Page 4-13). Install four screws (5) to secure the underbody to its vehicle.
  • Page 42 Canopy – Two-Passenger BODY AND TRIM Figure 4-13 Precedent Two-Passenger Canopy Page 4-18 2008 Electric Precedent Maintenance and Service Manual...

  • Page 43: Two-Passenger Canopy Installation

    BODY AND TRIM Canopy – Four-Passenger TWO-PASSENGER CANOPY INSTALLATION Install the front canopy supports. 1.1. Ensure the front supports are properly oriented to the correct side of the vehicle as shown (Figure 4-13, Page 4-18). The lower profile of each support follows the profile of the vehicle. If the supports are placed on the wrong side of the vehicle, they will not follow the vehicle’s profile.

  • Page 44: Four-Passenger Canopy Installation

    Canopy – Four-Passenger BODY AND TRIM Remove the nuts (14) and bolts (13) from the canopy (9) and the rear support (6). Lift canopy (9) away from front canopy supports (1) and rear support (6). Remove screws (5) securing front canopy support covers to front body. Slide canopy support covers (4) up front canopy supports (1) to gain access to bolts (2).
  • Page 45 BODY AND TRIM Canopy – Four-Passenger Figure 4-14 Precedent Four-Passenger Canopy 2008 Electric Precedent Maintenance and Service Manual Page 4-21...

  • Page 47: Section 5 - Accelerator And Brake Pedal Group

    SECTION 5 — ACCELERATOR AND BRAKE PEDAL GROUP DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. PEDAL GROUP See General Warnings on page 1-1. PEDAL GROUP REMOVAL Disconnect the battery cables and discharge the controller as instructed. See WARNINGS “To avoid unintentionally starting...”...
  • Page 48 Pedal Group ACCELERATOR AND BRAKE PEDAL GROUP Figure 5-2 Pedal Group Remove two screws (2) on the driver side of the pedal group and two screws (1) on the passenger side of the pedal group. Slightly lift pedal group from the vehicle to gain access to the connections to the MCOR on the passenger side of the pedal group.

  • Page 49: Mcor

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Figure 5-3 MCOR Removal MCOR The pedal group for the Precedent electric vehicle includes a Motor Controller Output Regulator (MCOR) mounted on the side of the pedal group. The MCOR detects the position of the GO pedal and sends a corresponding voltage to the motor controller.

  • Page 50: Accelerator Return Spring

    Pedal Group ACCELERATOR AND BRAKE PEDAL GROUP ACCELERATOR RETURN SPRING The accelerator return spring assembly (10) consists of a spring and T-shaped bar secured by crosspins (Figure 5-7, Page 5-5). The assembly is replaced as a unit. The replacement unit includes a pin that keeps the spring compressed so it can be installed in the pedal group.
  • Page 51 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Figure 5-7 Brake Pedal 2008 Electric Precedent Maintenance and Service Manual Page 5-5...

  • Page 52: Pedal Group Installation

    Pedal Group ACCELERATOR AND BRAKE PEDAL GROUP PEDAL GROUP INSTALLATION Place the MCOR on the pedal group and secure with two screws (1) (Figure 5-3, Page 5-3). Tighten screws to 23 in-lb (2.6 N·m). Connect the wire harness (12) to the MCOR (11) (Figure 5-2, Page 5-2). NOTE: Connectors will only fit together in one orientation.

  • Page 53: Section 6 - Wheel Brake Assemblies

    SECTION 6 — WHEEL BRAKE ASSEMBLIES DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. Asbestos Dust Warning • Some aftermarket brake shoes contain asbestos fiber, and asbestos dust is created when these brake mechanisms are handled.
  • Page 54 Brake Shoe Removal WHEEL BRAKE ASSEMBLIES Remove brake drums and badly worn brake shoes. 7.1. On the back of each brake cluster assembly, locate the heads of two brake shoe retainer pins. It may be necessary to remove sealant material around the head of each pin. 1400-18100-10220 Figure 6-1 Loosen Turnbuckle Figure 6-2 Shoe Retainer Pins...
  • Page 55 WHEEL BRAKE ASSEMBLIES Brake Shoe Removal Figure 6-4 Self-adjusting Wheel Brake Assembly Using needle nose pliers, turn the clip retainer pin (1) 90° to remove the shoe retainer clip (2) (Figure 6-5, Page 6-4). CAUTION • The brake shoes are under pressure and can release suddenly when brake shoe retainers are removed. 10.
  • Page 56 Brake Shoe Removal WHEEL BRAKE ASSEMBLIES 1400-18100-10222 1400-17700-10225 Figure 6-5 Remove Shoe Retainer Clip Figure 6-6 Remove Brake Shoes Figure 6-7 Remove Adjuster Wheel Figure 6-8 Lubricate Slide and Slide Plate Page 6-4 2008 Electric Precedent Maintenance and Service Manual...

  • Page 57: Brake Assembly Cleaning

    WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning BRAKE ASSEMBLY CLEANING See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. Carefully clean the brake backing plate and all of its mechanical components. Remove the rubber boot from backing plate and wipe with a clean damp cloth. Lubricate the slide (1) and slide plate (2) with dry moly lubricant (CCI P/N 1012151) on both sides of the backing plate (Figure 6-8, Page 6-4).
  • Page 58 Brake Assembly Cleaning WHEEL BRAKE ASSEMBLIES Figure 6-11 Apply Grease To Brake Adjuster Figure 6-12 Install Adjuster Wheel, Trailing Shoe Page 6-6 2008 Electric Precedent Maintenance and Service Manual...

  • Page 59: Brake Shoe Installation

    WHEEL BRAKE ASSEMBLIES Brake Shoe Installation BRAKE SHOE INSTALLATION See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. Turn the adjusting wheel screw so that the shoe slot is vertical, then position the trailing shoe in the slots in the shoe mounting block and adjuster assembly (Figure 6-12, Page 6-6).
  • Page 60 Brake Shoe Installation WHEEL BRAKE ASSEMBLIES Figure 6-15 Install Leading Shoe Figure 6-16 Check Shoe Positions Place a flatblade screwdriver under the adjusting arm (1) and raise the arm off of the adjusting wheel (2). While holding the arm (1) up, turn the wheel (2) upward until it stops (Figure 6-17, Page 6-8). Remove the screwdriver. Figure 6-17 Set Adjusting Wheel Install the rear axle onto the transaxle.
  • Page 61 WHEEL BRAKE ASSEMBLIES Brake Shoe Installation WARNING • Be sure retaining ring is properly seated in groove. If ring is not properly installed, the axle assembly will separate from the transaxle and damage the axle assembly and other components. Loss of vehicle control could result in severe personal injury or death.

  • Page 62: Brake Cable Equalizer Adjustment

    Brake Cable Equalizer Adjustment WHEEL BRAKE ASSEMBLIES BRAKE CABLE EQUALIZER ADJUSTMENT See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. After maintenance on the brake system is complete, lower the vehicle onto the floor. With the brake pedal in the full up or at rest position, adjust the turnbuckle (1) until the proper brake tension is achieved (Figure 6-18, Page 6-9).

  • Page 63: Brake Cluster Removal And Installation

    WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation BRAKE CLUSTER REMOVAL AND INSTALLATION See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. BRAKE CLUSTER REMOVAL Disconnect the battery cables and discharge the controller as instructed. See WARNINGS “To avoid unintentionally starting...”...
  • Page 64 Brake Cluster Removal and Installation WHEEL BRAKE ASSEMBLIES NOTE: There is a LEFT and RIGHT side axle. The splined portions on the axles that insert into the transaxle case are two different lengths. The longest length spline is the LEFT, or driver side axle. 4.1.

  • Page 65: Brake Cable Removal And Installation

    WHEEL BRAKE ASSEMBLIES Brake Cable Removal and Installation BRAKE CABLE REMOVAL AND INSTALLATION See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. NOTE: Beginning with Precedent vehicle serial number PD0918-020874, a new brake cable design (Figure 6-19, Page 6-13) and equalizer bracket design are used.

  • Page 66: Brake Cable Installation

    Brake Cable Removal and Installation WHEEL BRAKE ASSEMBLIES Figure 6-20 Loosen Brake Cables Rotate the bolt (5) and equalizer bracket (4) to the upright position then slip the cable heads out of the bracket. Remove nut (1) from the bolt (2) that secures front of the leaf spring (Figure 6-22, Page 6-14). Do not remove bolt (2).
  • Page 67 WHEEL BRAKE ASSEMBLIES Brake Cable Removal and Installation NOTE: The driver-side and passenger-side brake cables are not interchangeable. The driver-side cable is shorter than the passenger-side cable. Make sure the correct cable is used on the correct side. Be sure to orient the cable so that the clevis end goes to the wheel rather than to the equalizer bracket. Insert the end of the new brake cable through the hole in the frame (Figure 6-20, Page 6-14).

  • Page 69: Section 7 - Steering And Front Suspension

    SECTION 7 — STEERING AND FRONT SUSPENSION DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION Steering is controlled through a rack and pinion steering assembly that is connected by a steering column to a steering wheel.

  • Page 70: Steering Wheel Installation

    Steering Column STEERING AND FRONT SUSPENSION Figure 7-1 Steering Wheel Removal Figure 7-2 Steering Wheel Puller STEERING WHEEL INSTALLATION NOTE: To minimize corrosion and to make future removal of the steering wheel easier, apply a small amount of oil or anti-seize compound to steering shaft before installing the steering wheel.

  • Page 71: Steering Column Installation

    STEERING AND FRONT SUSPENSION Steering Column Figure 7-3 Steering Column STEERING COLUMN INSTALLATION For ease of assembly and to prevent corrosion, apply a light coat of anti-seize or lubricating compound to the splined stud extending from the steering gear. 2008 Electric Precedent Maintenance and Service Manual Page 7-3...

  • Page 72: Rack And Pinion

    Rack and Pinion STEERING AND FRONT SUSPENSION Insert the end of the steering column with the universal joint through the front underbody. Position universal joint over splined stud on the steering gear. Leave bolt (11) loose until steering column is mounted to frame in step 3 (Figure 7-3, Page 7-3).

  • Page 73: Rack And Pinion Disassembly

    STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION DISASSEMBLY Remove the two tie rod ends (12) and inspect for excessive wear (Figure 7-5, Page 7-6). Remove clamps (10 and 21) from bellows (9) (Figure 7-5, Page 7-6). NOTE: If the dust seal bellows are secured with a metal clamp, remove the clamp. Do not reuse the clamp when the rack and pinion is reassembled.
  • Page 74 Rack and Pinion STEERING AND FRONT SUSPENSION Figure 7-5 Steering Gear Page 7-6 2008 Electric Precedent Maintenance and Service Manual...

  • Page 75: Rack And Pinion Assembly

    STEERING AND FRONT SUSPENSION Rack and Pinion Figure 7-6 Remove Dust Seal Figure 7-7 Pinion Snap Rings 1. Press Ram 2. Pinion Gear 3. Bearing Figure 7-8 Remove Pinion from Housing Figure 7-9 Remove Bearing from Pinion RACK AND PINION ASSEMBLY Apply a liberal amount of EP grease to the teeth of the rack (18), then slide the rack through the bushing (7) and housing (17) (Figure 7-5, Page 7-6).

  • Page 76: Rack And Pinion Installation

    Rack and Pinion STEERING AND FRONT SUSPENSION CAUTION • Do not force the pinion-bearing assembly into the housing. The gear teeth or the small bearing could be damaged. Install the large snap ring (2). Use a socket (1) to apply pressure evenly and press in a new dust seal (2) (Figure 7-10, Page 7-9). Apply a small amount of grease to the rack guide (16) where it comes into contact with the rack (18) (Figure 7-5, Page 7-6).
  • Page 77 STEERING AND FRONT SUSPENSION Rack and Pinion Figure 7-10 Press In Dust Seal Figure 7-11 Install Ball Joint Figure 7-12 Rack and Pinion Adjustment Figure 7-13 Rack and Pinion Resistance 2008 Electric Precedent Maintenance and Service Manual Page 7-9...

  • Page 78: Front Suspension

    Front Suspension STEERING AND FRONT SUSPENSION FRONT SUSPENSION See General Warnings on page 1-1. LUBRICATION Two grease fittings are provided (one in each spindle housing). Lubricate these fittings at the recommended interval with the proper lubricant. See Periodic Lubrication Schedule on page 10-5. CAUTION •...
  • Page 79 STEERING AND FRONT SUSPENSION Front Suspension Figure 7-14 Check Camber Figure 7-15 Adjust Camber Toe-in Adjustment On a level surface, roll the vehicle forward, then stop. Make sure the front wheels are pointed straight ahead. Do not turn the steering wheel again during this procedure. On each front tire, mark (as closely as possible) the center of the tread face that is oriented toward the rear of the vehicle.

  • Page 80: Front Suspension Components

    Front Suspension Components STEERING AND FRONT SUSPENSION 6.1. Loosen the jam nut on each tie rod end (1) (Figure 7-17, Page 7-11). 6.2. Remove the retaining pin (2) and nut (3) that secure the tie rod to the spindle. Raise the male threads out of the spindle.

  • Page 81: Leaf Spring Removal

    STEERING AND FRONT SUSPENSION Front Suspension Components LEAF SPRING REMOVAL Disconnect the battery cables and discharge the controller as instructed. See WARNINGS “To avoid unintentionally starting...” and “After disconnecting the batteries, wait 90 seconds...” in General Warnings on page 1-1. Loosen lug nuts on both front wheels and raise front of vehicle with a chain hoist or floor jack.

  • Page 82: Control Arm Removal

    Front Suspension Components STEERING AND FRONT SUSPENSION Install the kingpin (7) over the leaf spring eye. Insert the bolt (8) (Figure 7-19, Page 7-16). Tighten the bolt to 30 ft-lb (41 N·m). Install the wave washer (6) on the kingpin. Install the steering spindle on the kingpin.
  • Page 83 STEERING AND FRONT SUSPENSION Front Suspension Components 1311 Figure 7-18 Upper Front Suspension Assembly 2008 Electric Precedent Maintenance and Service Manual Page 7-15...
  • Page 84 Front Suspension Components STEERING AND FRONT SUSPENSION 1312 Figure 7-19 Lower Front Suspension Assembly Page 7-16 2008 Electric Precedent Maintenance and Service Manual...

  • Page 85: Front Wheel Bearings And Hubs

    STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs FRONT WHEEL BEARINGS AND HUBS See General Warnings on page 1-1. NOTE: The front wheel bearings are pressed into the spindle and are not serviceable. If excessive free-play is detected the entire hub should be replaced. FRONT WHEEL FREE PLAY INSPECTION Disconnect the battery cables and discharge the controller as instructed.
  • Page 86 Front Wheel Bearings and Hubs STEERING AND FRONT SUSPENSION Figure 7-20 Front Wheel Hub Page 7-18 2008 Electric Precedent Maintenance and Service Manual...

  • Page 87: Section 8 - Wheels And Tires

    SECTION 8 — WHEELS AND TIRES DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION Maximum tire life and good vehicle handling qualities are directly related to proper wheel and tire care. •...

  • Page 88: Tires

    Tires WHEELS AND TIRES TIRES See General Warnings on page 1-1. TIRE REMOVAL NOTE: Tire must be removed or installed from the valve stem side of the rim. Remove the tire and wheel assembly from the vehicle as instructed above. Remove the valve cap and valve core and allow air to escape from the tire.

  • Page 89: Tire Installation

    Small holes in the casing can be plugged using a standard automotive tubeless tire repair kit available at your local Club Car dealer. When the cause of the air leak has been determined, remove tire from the rim and repair as required. See Tire Removal on page 8-2.
  • Page 90 Tires WHEELS AND TIRES Figure 8-2 Inflate Tire Page 8-4 2008 Electric Precedent Maintenance and Service Manual...

  • Page 91: Section 9 - Rear Suspension

    SECTION 9 — REAR SUSPENSION DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION The rear suspension and powertrain of the vehicle move independently from the vehicle frame. It consists of two leaf springs controlled by two shock absorbers mounted between the springs and the vehicle frame.

  • Page 92: Leaf Springs (Two-Passenger Vehicles)

    Leaf Springs (Two-Passenger Vehicles) REAR SUSPENSION LEAF SPRINGS (TWO-PASSENGER VEHICLES) See General Warnings on page 1-1. LEAF SPRING REMOVAL (TWO-PASSENGER VEHICLES) Disconnect the battery cables and discharge the controller as instructed. See WARNINGS “To avoid unintentionally starting...” and “After disconnecting the batteries, wait 90 seconds...” in General Warnings on page 1-1.

  • Page 93: Leaf Spring Installation (Two-Passenger Vehicles)

    REAR SUSPENSION Leaf Springs (Two-Passenger Vehicles) Figure 9-1 Support Vehicle on Jack Stands Figure 9-2 Disconnect Brake Cable LEAF SPRING INSTALLATION (TWO-PASSENGER VEHICLES) To install the springs, reverse the removal procedure. See following CAUTION. CAUTION • When positioning the spring on the transaxle, be sure to insert the locating bolt on the spring in the locating hole in the transaxle saddle.

  • Page 94: Leaf Springs (Four-Passenger Vehicles)

    Leaf Springs (Four-Passenger Vehicles) REAR SUSPENSION Figure 9-3 Rear Suspension Assembly and Mounting (Two-Passenger Vehicles) LEAF SPRINGS (FOUR-PASSENGER VEHICLES) See General Warnings on page 1-1. LEAF SPRING REMOVAL (FOUR-PASSENGER VEHICLES) Disconnect the battery cables and discharge the controller as instructed. See WARNINGS “To avoid unintentionally starting...”...

  • Page 95: Leaf Spring Installation (Four-Passenger Vehicles)

    REAR SUSPENSION Leaf Springs (Four-Passenger Vehicles) Loosen, but do not remove, lug nuts on tire and wheel assembly on the side from which the spring is to be removed. 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 forward of the spring mounting tabs.
  • Page 96 Leaf Springs (Four-Passenger Vehicles) REAR SUSPENSION Figure 9-4 Rear Suspension Assembly and Mounting (Four-Passenger Vehicles) Page 9-6 2008 Electric Precedent Maintenance and Service Manual...

  • Page 97: 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 serviced. 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 vehicle.
  • Page 98 General Warning PERIODIC MAINTENANCE WARNING • Use insulated tools when working near batteries or electrical connections. Use extreme caution to avoid shorting of components or wiring. • Turn key switch OFF and remove key, place Forward/Reverse switch in the NEUTRAL position, and chock the wheels prior to servicing the vehicle.

  • Page 99: General Information

    Any vehicle not functioning correctly should be removed from use until it is properly repaired. This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service. PERIODIC SERVICE SCHEDULE WARNING •...
  • Page 100 Periodic Service Schedule PERIODIC MAINTENANCE Both the Periodic Service Schedule and the Periodic Lubrication Schedule must be followed to keep vehicle in optimum operating condition. PERIODIC SERVICE SCHEDULE – ELECTRIC VEHICLES REGULAR INTERVAL SERVICE See Pre-Operation and Daily Safety Checklist Pre-Operation and Daily Safety Checklist in the appropriate Owner’s Manual Daily service by owner...

  • Page 101: Periodic Lubrication Schedule

    PERIODIC MAINTENANCE Periodic Lubrication Schedule PERIODIC SERVICE SCHEDULE – ELECTRIC VEHICLES REGULAR INTERVAL SERVICE If batteries are not performing as expected, Batteries see Section 16 — Batteries . Annual service by trained technician only (every 100 hours of operation or 200 rounds Lubricate all rotating joints.

  • Page 103: Section 11 - Iq System Troubleshooting

    SECTION 11 — IQ SYSTEM TROUBLESHOOTING DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. • Shorting of battery terminals can cause personal injury or death. – Do not place component mounting plate directly on top of batteries when removing or installing plate.

  • Page 104: Wiring Diagrams

    Wiring Diagrams IQ SYSTEM TROUBLESHOOTING WIRING DIAGRAMS SP ADE #16 BLK/WHT #18 BLK 10-AMP FUSE SONIC LEFT #12 BLUE #12 BLUE #16 BROWN #18 BRN WELD TAILLIGHT #18 RED #16 WHITE #16 BLACK/WHITE #16 BLK/WHT #18 BLK #16 BROWN #18 BRN RIGHT #16 BROWN #6 RED...
  • Page 105 IQ SYSTEM TROUBLESHOOTING Wiring Diagrams #12 BLUE #18 WHITE #16 PINK TOW SWITCH DIODE #16 R ED #16 BLUE #16 BLUE #18 R ED RECEPTACLE #10 R ED #10 BLACK #18 BRO WN/WHITE SINGLE P OSITION CONNECTOR SP ADE TERMINAL BATTERIES #18 YELLOW 6 PIN GR OUP...
  • Page 106 Wiring Diagrams IQ SYSTEM TROUBLESHOOTING USED WHEN THERE ARE LIGHTS BUT NO TURN S IGNAL. NORMALLY OPEN MOM ENTARY PUSH BU TTON FOR HORN 9-PIN #16 ORANGE CONNECT OR #16 BLUE/WHITE #16 WHITE #16 YELLOW SONIC #16 BROWN/WHITE WELD FLASHER UNIT #16 BLACK #16 ORANGE...
  • Page 107 IQ SYSTEM TROUBLESHOOTING Wiring Diagrams HEADLIGHT ASSEMBLY DC - DC HORN CONVERTER SONIC 20 AMP WELD #16 BLACK FUS E SONIC WELD #18 O RANGE DIODE #16 BLACK/WHITE #12 BLACK SON IC WELD #16 BLACK SON IC WELD CONNE CTS TO MAIN HARNESS. SEE FIGURE S 11-1 AND 11-2.
  • Page 108 Wiring Diagrams IQ SYSTEM TROUBLESHOOTING KEY SWITCH OP TIONAL BATTERY INDICATOR 9-PIN CONNECTOR. SONIC WELD CONNECTS TO MAIN HARNESS. SEE FIGURES 11-1 AND 11-2. #18 RED #16 BLUE #16 GREEN/RED #18 BLACK/YELLOW #18 BROWN/WHITE #18 BROWN/WHITE #18 ORANGE/WHITE #18 RED #18 YELLOW #18 GREEN REVERS E...

  • Page 109: Troubleshooting

    TROUBLESHOOTING THE VEHICLE WITH THE IQDM Club Car recommends the use of the IQDM handset for troubleshooting vehicles equipped with the IQ electrical system. Troubleshooting Guide 1 is to be used in conjunction with the IQDM handset. See Section 13 — IQ Display Module (IQDM) and IQDM-P Diagnostics: IQ System for operating instructions.

  • Page 110: Troubleshooting Guide 1

    Troubleshooting IQ SYSTEM TROUBLESHOOTING TROUBLESHOOTING GUIDE 1 The following troubleshooting guide is intended for use with an IQDM handset. See following NOTE. NOTE: Before troubleshooting the vehicle, check the diagnostic history from the Special Diagnostics Menu. Note any fault codes. TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES...
  • Page 111 IQ SYSTEM TROUBLESHOOTING Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Disconnect the batteries and allow the speed controller capacitors to discharge. See WARNING “To avoid unintentionally Speed controller logic malfunction starting...” in General Warnings on page 1-1. Reconnect the batteries and see if the Test Menu –...
  • Page 112 Troubleshooting IQ SYSTEM TROUBLESHOOTING TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Diagnostic Menu – MAIN COIL FAULT fault Replace solenoid. See Solenoid Removal on code or Diagnostic Menu – MAIN DROPOUT Solenoid coil has failed in an open condition page 15-19.

  • Page 113: Troubleshooting Guide 2

    IQ SYSTEM TROUBLESHOOTING Troubleshooting TROUBLESHOOTING GUIDE 2 TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Batteries – Batteries discharged Charge batteries Check vehicle wiring. See Wiring Diagrams Batteries – Battery connections on page 11-2. Battery charger is connected to the vehicle Disconnect the battery charger from the –...
  • Page 114 Troubleshooting IQ SYSTEM TROUBLESHOOTING TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Test Procedure 21 – Motor Speed Sensor on Speed sensor disconnected or failed page 11-33 To change the programmed top speed of the Incorrect speed setting vehicle, an IQDM-P handset must be used Check vehicle wiring.

  • Page 115: Test Procedures

    IQ SYSTEM TROUBLESHOOTING Test Procedures TEST PROCEDURES Using the following procedures, the entire IQ electrical system can be tested without major disassembly of the vehicle. WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.
  • Page 116 Test Procedures IQ SYSTEM TROUBLESHOOTING 18 – Onboard Computer Silicon-Controlled Rectifier (SCR) Circuit 19 – Onboard Computer Gray Wire 20 – Voltage at Charger Receptacle Red Wire Socket 21 – Motor Speed Sensor 22 – Solenoid Continuity 23 – Forward/Reverse Rocker Switch 24 –...
  • Page 117 IQ SYSTEM TROUBLESHOOTING Test Procedures WAVETEK 1000 WAVETEK 1000 2000 200k 2000 200k 200nA 200nA 1000 --- FUSED 750V 1000 --- FUSED 750V (Viewed from driver side of vehicle) (Viewed from driver side of vehicle) 1. RED probe to battery no. 1 (+). 1.
  • Page 118 Test Procedures IQ SYSTEM TROUBLESHOOTING 6.2. Using a multimeter set to 200 volts DC, place the black (–) probe on the battery no. 4 (4 x 12-Volt battery set) or battery no. 6 (6 x 8-Volt battery set) negative post and place the red (+) probe (with insulation-piercing probe) on the red 18-gauge wire (harness side of six-pin connector).
  • Page 119 IQ SYSTEM TROUBLESHOOTING Test Procedures Access the Test menu and select THROTTLE % by using the SCROLL DISPLAY buttons. The IQDM should indicate 0 % with the pedal not pressed. While monitoring the IQDM display screen, slowly press the accelerator pedal. As the pedal is pressed, the IQDM should indicate a rise from 0 % (pedal not pressed) to 100 % (pedal fully pressed).
  • Page 120 Test Procedures IQ SYSTEM TROUBLESHOOTING 8.6. Using a multimeter set for 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 white/black wire with an insulation-piercing probe.
  • Page 121 IQ SYSTEM TROUBLESHOOTING Test Procedures If the IQDM display screen goes blank after 90 seconds, the Tow/Run switch and connecting wires are operating correctly. If the IQDM display screen is still active after 90 seconds, the switch has failed closed. Replace the Tow/Run switch.
  • Page 122 Test Procedures IQ SYSTEM TROUBLESHOOTING (Viewed from driver side of vehicle) (Viewed from driver side of vehicle) 1. RED probe to battery no. 1 (+). 1. RED probe to battery no. 1 (+). 2. BLACK probe to battery no. 4 (-). 2.
  • Page 123 IQ SYSTEM TROUBLESHOOTING Test Procedures 4.3. If the IQDM does not indicate that KEY INPUT is ON when the key switch is in the ON position, proceed to the following procedure, Key Switch and MCOR Limit Switch Circuit Test without the IQDM Handset. If the key switch functions as described, proceed to the following step.
  • Page 124 Test Procedures IQ SYSTEM TROUBLESHOOTING 5.2. With Tow/Run switch in the RUN position, key switch in the ON position, and Forward/Reverse rocker switch in the NEUTRAL position, the voltage reading should be zero volts. When the accelerator pedal is pressed, the voltage reading should be approximately 48 volts (full battery voltage).
  • Page 125 IQ SYSTEM TROUBLESHOOTING Test Procedures SPEED CONTROLLER 16-PIN CONNECTOR WIRE TEST PROCEDURE Pin 1 – White/Black (18-gauge) Pin 2 – Yellow (18-gauge) Test Procedure 10 – Pins 1, 2, and 3 on page 11-23 Pin 3 – Purple (18-gauge) Pin 4 – Open (No wire) Pin 5 –...
  • Page 126 Test Procedures IQ SYSTEM TROUBLESHOOTING WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 20k Ohm Setting (reading with pedal not pressed) Figure 11-13 Pins 1, 2, and 3 Test Using a multimeter set for 20k ohms, insert the red (+) probe of the multimeter into pin 2 (yellow wire) at the 16-pin connector.
  • Page 127 IQ SYSTEM TROUBLESHOOTING Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with OBC powered-up and battery charger disconnected) Figure 11-14 Pin 5 Test Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first. Tighten battery terminals to 110 in-lb (12.4 N·m).
  • Page 128 Test Procedures IQ SYSTEM TROUBLESHOOTING WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with OBC powered-up and accelerator pedal pressed) Figure 11-15 Pin 6 Test Using a multimeter set for 200 volts DC, insert the red (+) probe of the multimeter into pin 6 (green wire) of the 16-pin connector.
  • Page 129 IQ SYSTEM TROUBLESHOOTING Test Procedures TEST PROCEDURE 13 – Pin 7 See General Warnings on page 1-1. Pin 7 in the 16-pin connector provides a connection point for the reverse buzzer to the speed controller. Disconnect the battery cables and discharge the controller as instructed. See WARNINGS “To avoid unintentionally starting...”...
  • Page 130 Test Procedures IQ SYSTEM TROUBLESHOOTING TEST PROCEDURE 14 – Pins 8 and 16 See General Warnings on page 1-1. Pins 8 and 16 in the 16-pin connector provide a connection point for the Forward/Reverse rocker switch to the speed controller. The switch provides a +48 volt signal to the speed controller through pin 8 when the Forward/Reverse switch is in the FORWARD position and provides a +48 volt signal on pin 16 when the Forward/Reverse switch is in the REVERSE position.
  • Page 131 IQ SYSTEM TROUBLESHOOTING Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with Tow/Run switch in RUN and Forward/Reverse switch in FORWARD) Figure 11-17 Pins 8 and 16 Test TEST PROCEDURE 15 – Pin 9 See General Warnings on page 1-1.
  • Page 132 Test Procedures IQ SYSTEM TROUBLESHOOTING WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with Tow/Run switch in RUN position) Figure 11-18 Pin 9 Test With the Tow/Run switch in the RUN position, the multimeter should indicate full battery voltage (approximately 48 volts).
  • Page 133 IQ SYSTEM TROUBLESHOOTING Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with Tow/Run switch in RUN and key switch in the ON position) Figure 11-19 Pin 10 Test With the key switch in the ON position, the multimeter should indicate full battery voltage (approximately 48 volts). With the key switch in the OFF position, the reading should be zero volts.
  • Page 134 Test Procedures IQ SYSTEM TROUBLESHOOTING Figure 11-20 Pin 12 Test The solenoid should click when the key switch is placed in the ON position. If any other activity is observed, check the following items: – Continuity of the wires in the wire harness –...
  • Page 135 IQ SYSTEM TROUBLESHOOTING Test Procedures TEST PROCEDURE 19 – Onboard Computer Gray Wire See General Warnings on page 1-1. With batteries connected and the DC cord disconnected, pull back on the boot (1) on the gray wire (2) connection at the OBC (3) (Figure 11-21, Page 11-33). Using a multimeter set to 200 volts DC, connect the red (+) probe to the positive post of battery no.
  • Page 136 Test Procedures IQ SYSTEM TROUBLESHOOTING CAUTION • Perform the following procedure only on a level surface. To avoid injury or property damage, ensure that the path of the vehicle is clear before pushing vehicle. Turn the key switch to the OFF position and place the Forward/Reverse switch in the NEUTRAL position. Connect the IQDM to the vehicle.
  • Page 137 IQ SYSTEM TROUBLESHOOTING Test Procedures 6.1. Raise one rear wheel off ground. Slowly turn the rear wheel to rotate the motor armature. As the armature rotates, the voltage reading should alternate from zero to approximately 4.85 volts. The voltage reading will fluctuate from zero to 4.85 volts and back to zero four times for each revolution of the motor armature.
  • Page 138 Test Procedures IQ SYSTEM TROUBLESHOOTING page 11-2. Also check the 16-pin connector at the speed controller. See Test Procedure 9 – 16-Pin Connector on page 11-22. Test REVERSE INPUT. 4.1. Access the Test menu and select REVERSE INPUT by using the SCROLL DISPLAY buttons. The IQDM should indicate OFF when the Forward/Reverse switch is in the NEUTRAL or FORWARD position.
  • Page 139 IQ SYSTEM TROUBLESHOOTING Test Procedures 7.1. If the voltage reading is correct, replace the reverse buzzer. 7.2. If reading is zero volts, check orange/white wire continuity and connection at Pin 7 in 16-Pin connector. 7.3. If there is no continuity in the orange/white wire, or the Pin 7 terminal in the 16-Pin connector is not properly seated, repair or replace as required.

  • Page 140: Communication Display Module (Cdm)

    Func3 - Func4 - Last charge termination type (1 = Incomplete, 2 = DVDT, 4 = Normal, 8 = Max. timer). POWER Club Car PART #17075 1. Low Battery 2. Display Window 3. Function Button 2500-19200-10300 Figure 11-22 CDM The CDM can be used to retrieve from the onboard computer four important items of information that can be useful in troubleshooting the IQ System vehicle.

  • Page 141: Using The Cdm To Retrieve Data From The Onboard Computer

    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. 2008 Electric Precedent Maintenance and Service Manual Page 11-39...
  • Page 142 CDM Troubleshooting Guide IQ SYSTEM TROUBLESHOOTING OBC Will Not Communicate With The CDM CDM battery Failed CDM unit Failed OBC is discharged Replace CDM battery Replace CDM Replace OBC Failed Dash Light Replace Dash Light OBC program is "locked-up" OBC is in a Batteries discharged powerdown mode Remove "+"...

  • Page 143: Section 12 - Excel System Troubleshooting

    SECTION 12 — EXCEL SYSTEM TROUBLESHOOTING DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. • Shorting of battery terminals can cause personal injury or death. – Do not place component mounting plate directly on top of batteries when removing or installing plate.

  • Page 144: Wiring Diagrams

    Wiring Diagrams EXCEL SYSTEM TROUBLESHOOTING WIRING DIAGRAMS WD1034035B-L Figure 12-1 Wiring Diagram – Excel System Page 12-2 2008 Electric Precedent Maintenance and Service Manual...
  • Page 145 EXCEL SYSTEM TROUBLESHOOTING Wiring Diagrams BATTERIES 6_ BLK 6_ RED 10 _O RG CONTROLLER 10 _BLU 6_ WHT 6_ GRN WD1034035B-R Figure 12-2 Wiring Diagram – Excel System (Continued) 2008 Electric Precedent Maintenance and Service Manual Page 12-3...
  • Page 146 Wiring Diagrams EXCEL SYSTEM TROUBLESHOOTING USED WHEN THERE ARE LIGHTS BUT NO TURN S IGNAL. NORMALLY OPEN MOM ENTARY PUSH BU TTON FOR HORN 9-PIN #16 ORANGE CONNECT OR #16 BLUE/WHITE #16 WHITE #16 YELLOW SONIC #16 BROWN/WHITE WELD FLASHER UNIT #16 BLACK #16 ORANGE...
  • Page 147 EXCEL SYSTEM TROUBLESHOOTING Wiring Diagrams HEADLIGHT ASSEMBLY DC - DC HORN CONVERTER SONIC 20 AMP WELD #16 BLACK FUS E SONIC WELD #18 O RANGE DIODE #16 BLACK/WHITE #12 BLACK SON IC WELD #16 BLACK SON IC WELD CONNE CTS TO MAIN HARNESS. SEE FIGURE S 11-1 AND 11-2.
  • Page 148 Wiring Diagrams EXCEL SYSTEM TROUBLESHOOTING KEY SWITCH OP TIONAL BATTERY INDICATOR 9-PIN CONNECTOR. SONIC WELD CONNECTS TO MAIN HARNESS. SEE FIGURES 11-1 AND 11-2. #18 RED #16 BLUE #16 GREEN/RED #18 BLACK/YELLOW #18 BROWN/WHITE #18 BROWN/WHITE #18 ORANGE/WHITE #18 RED #18 YELLOW #18 GREEN REVERS E...

  • Page 149: Troubleshooting

    TROUBLESHOOTING THE VEHICLE WITH THE IQDM Club Car recommends the use of the IQDM handset for troubleshooting vehicles equipped with the Excel electrical system. Troubleshooting Guide 1 is to be used in conjunction with the IQDM handset. See IQ Display Module (IQDM) and IQDM-P Diagnostics: Excel System on page 14-1 for operating instructions.
  • Page 150 Troubleshooting EXCEL SYSTEM TROUBLESHOOTING TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Loose or disconnected three-pin connector at Repair and/or connect the three-pin connector the MCOR or broken wire to the MCOR Test Menu – THROTTLE % value does not increase as the accelerator pedal is pressed Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector...
  • Page 151 EXCEL SYSTEM TROUBLESHOOTING Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Disconnect the batteries and allow the speed controller capacitors to discharge. See WARNING “To avoid unintentionally Speed controller logic malfunction starting...” in General Warnings on page 1-1. Reconnect the batteries and see if the Test Menu –...
  • Page 152 Troubleshooting EXCEL SYSTEM TROUBLESHOOTING TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Diagnostic Menu – MAIN COIL FAULT fault Replace solenoid. See Solenoid Removal on code or Diagnostic Menu – MAIN DROPOUT Solenoid coil has failed in an open condition page 15-20.

  • Page 153: Troubleshooting Guide 2

    EXCEL SYSTEM TROUBLESHOOTING Troubleshooting TROUBLESHOOTING GUIDE 2 TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Batteries – Batteries discharged Charge batteries Check vehicle wiring. See Wiring Diagrams Batteries – Battery connections on page 12-2. Battery charger is connected to the vehicle Disconnect the battery charger from the –...
  • Page 154 Troubleshooting EXCEL SYSTEM TROUBLESHOOTING TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Test Procedure 21 – Motor Speed Sensor on Speed sensor disconnected or failed page 12-33 To change the programmed top speed of the Incorrect speed setting vehicle, an IQDM-P handset must be used Check vehicle wiring.

  • Page 155: Test Procedures

    EXCEL SYSTEM TROUBLESHOOTING Test Procedures TEST PROCEDURES Using the following procedures, the entire electrical system can be tested without major disassembly of the vehicle. WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.
  • Page 156 Test Procedures EXCEL SYSTEM TROUBLESHOOTING 20 – Voltage at Charger Receptacle Red Wire Socket 21 – Motor Speed Sensor 22 – Solenoid Continuity 23 – Forward/Reverse Rocker Switch 24 – Reverse Buzzer 25 – Rebooting the Onboard Computer 26 – Battery Warning Light TEST PROCEDURE 1 –...
  • Page 157 EXCEL SYSTEM TROUBLESHOOTING Test Procedures WAVETEK 1000 WAVETEK 1000 2000 200k 2000 200k 200nA 200nA 1000 --- FUSED 750V 1000 --- FUSED 750V (Viewed from driver side of vehicle) (Viewed from driver side of vehicle) 1. RED probe to battery no. 1 (+). 1.
  • Page 158 Test Procedures EXCEL SYSTEM TROUBLESHOOTING 6.2. Using a multimeter set to 200 volts DC, place the black (–) probe on the battery no. 4 (4 x 12-Volt battery set) or battery no. 6 (6 x 8-Volt battery set) negative post and place the red (+) probe (with insulation-piercing probe) on the red 18-gauge wire (harness side of six-pin connector).
  • Page 159 EXCEL SYSTEM TROUBLESHOOTING Test Procedures The IQDM should indicate 0 % with the pedal not pressed. While monitoring the IQDM display screen, slowly press the accelerator pedal. As the pedal is pressed, the IQDM should indicate a rise from 0 % (pedal not pressed) to 100 % (pedal fully pressed).
  • Page 160 Test Procedures EXCEL SYSTEM TROUBLESHOOTING 8.6. Using a multimeter set for 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 white wire with an insulation-piercing probe.
  • Page 161 EXCEL SYSTEM TROUBLESHOOTING Test Procedures TEST PROCEDURE 6 – Tow/Run Switch See General Warnings on page 1-1. Tow/Run Switch Test with the IQDM Handset With the Tow/Run switch in the RUN position, connect the IQDM to the vehicle. Immediately after the IQDM is connected to the vehicle, the screen should display a copyright notice and the IQDM model number.
  • Page 162 Test Procedures EXCEL SYSTEM TROUBLESHOOTING TEST PROCEDURE 7 – Battery Pack Voltage (Under Load) See General Warnings on page 1-1. Be sure the batteries are fully charged and that the electrolyte level is correct in all cells. Connect the tester leads to the positive (+) post of battery no.1 and negative (–) post of battery no. 4 (Figure 12-9, Page 12-20) or battery no.
  • Page 163 EXCEL SYSTEM TROUBLESHOOTING Test Procedures Test the key switch. 4.1. Access the Test menu and select KEY INPUT by using the SCROLL DISPLAY buttons. The IQDM should indicate OFF when the key switch is in the OFF position. 4.2. While monitoring the IQDM display screen, turn the key switch to the ON position. The IQDM should indicate ON.
  • Page 164 Test Procedures EXCEL SYSTEM TROUBLESHOOTING WARNING • The Forward/Reverse switch must be in the neutral position to avoid personal injury due to contact with rotating wheels. 5.2. With Tow/Run switch in the RUN position, key switch in the ON position, and Forward/Reverse rocker switch in the NEUTRAL position, the voltage reading should be zero volts.
  • Page 165 EXCEL SYSTEM TROUBLESHOOTING Test Procedures SPEED CONTROLLER 16-PIN CONNECTOR WIRE TEST PROCEDURE Pin 1 – White (18-gauge) Test Procedure 10 – Pins 1, 2, and 3 on page 12-23 Pin 2 – Yellow (18-gauge) Also for Pin 3 Test continuity of wire and perform Test Procedure 21 – Motor Speed Sensor on page 12-33 Pin 3 –...
  • Page 166 Test Procedures EXCEL SYSTEM TROUBLESHOOTING WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 20k Ohm Setting (reading with pedal not pressed) Figure 12-11 Pins 1, 2, and 3 Test Using a multimeter set for 20k ohms, insert the red (+) probe of the multimeter into pin 2 (yellow wire) at the 16-pin connector.
  • Page 167 EXCEL SYSTEM TROUBLESHOOTING Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with OBC powered-up and battery charger disconnected) Figure 12-12 Pin 5 Test Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first. Tighten battery terminals to 110 in-lb (12.4 N·m).
  • Page 168 Test Procedures EXCEL SYSTEM TROUBLESHOOTING WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with OBC powered-up and accelerator pedal pressed) Figure 12-13 Pin 6 Test Using a multimeter set for 200 volts DC, insert the red (+) probe of the multimeter into pin 6 (green wire) of the 16-pin connector.
  • Page 169 EXCEL SYSTEM TROUBLESHOOTING Test Procedures TEST PROCEDURE 13 – Pin 7 See General Warnings on page 1-1. Pin 7 in the 16-pin connector provides a connection point for the reverse buzzer to the speed controller. Disconnect the battery cables and discharge the controller as instructed. See WARNINGS “To avoid unintentionally starting...”...
  • Page 170 Test Procedures EXCEL SYSTEM TROUBLESHOOTING TEST PROCEDURE 14 – Pins 8 and 16 See General Warnings on page 1-1. Pins 8 and 16 in the 16-pin connector provide a connection point for the Forward/Reverse rocker switch to the speed controller. The switch provides a +48 volt signal to the speed controller through pin 8 when the Forward/Reverse switch is in the FORWARD position and provides a +48 volt signal on pin 16 when the Forward/Reverse switch is in the REVERSE position.
  • Page 171 EXCEL SYSTEM TROUBLESHOOTING Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with Tow/Run switch in RUN and Forward/Reverse switch in FORWARD) Figure 12-15 Pins 8 and 16 Test TEST PROCEDURE 15 – Pin 9 See General Warnings on page 1-1.
  • Page 172 Test Procedures EXCEL SYSTEM TROUBLESHOOTING WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with Tow/Run switch in RUN position) Figure 12-16 Pin 9 Test With the Tow/Run switch in the RUN position, the multimeter should indicate full battery voltage (approximately 48 volts).
  • Page 173 EXCEL SYSTEM TROUBLESHOOTING Test Procedures WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV Setting (reading with Tow/Run switch in RUN and key switch in the ON position) Figure 12-17 Pin 10 Test Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first. Tighten battery terminals to 110 in-lb (12.4 N·m).
  • Page 174 Test Procedures EXCEL SYSTEM TROUBLESHOOTING CAUTION • Do not fully insert probes into the 16-pin plug. Doing so can result in a poor connection. Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first. Tighten battery terminals to 110 in-lb (12.4 N·m).
  • Page 175 EXCEL SYSTEM TROUBLESHOOTING Test Procedures – Black wire terminal socket in the charger receptacle. – Onboard computer gray wire. See Test Procedure 19 – Onboard Computer Gray Wire on page 12-33. – Red wire at the charger receptacle. See Test Procedure 20 – Voltage at Charger Receptacle Red Wire Socket on page 12-33.
  • Page 176 Test Procedures EXCEL SYSTEM TROUBLESHOOTING Motor Speed Sensor Test with the IQDM Handset CAUTION • Perform the following procedure only on a level surface. To avoid injury or property damage, ensure that the path of the vehicle is clear before pushing vehicle. Turn the key switch to the OFF position and place the Forward/Reverse switch in the NEUTRAL position.
  • Page 177 EXCEL SYSTEM TROUBLESHOOTING Test Procedures 6.1. Raise one rear wheel off ground. Slowly turn the rear wheel to rotate the motor armature. As the armature rotates, the voltage reading should alternate from zero to approximately 4.85 volts. The voltage reading will fluctuate from zero to 4.85 volts and back to zero four times for each revolution of the motor armature.
  • Page 178 Test Procedures EXCEL SYSTEM TROUBLESHOOTING page 12-2. Also check the 16-pin connector at the speed controller. See Test Procedure 9 – 16-Pin Connector on page 12-22. Test REVERSE INPUT. 4.1. Access the Test menu and select REVERSE INPUT by using the SCROLL DISPLAY buttons. The IQDM should indicate OFF when the Forward/Reverse switch is in the NEUTRAL or FORWARD position.
  • Page 179 EXCEL SYSTEM TROUBLESHOOTING Test Procedures 7.1. If the voltage reading is correct, replace the reverse buzzer. 7.2. If reading is zero volts, check orange/white wire continuity and connection at Pin 7 in 16-Pin connector. 7.3. If there is no continuity in the orange/white wire, or the Pin 7 terminal in the 16-Pin connector is not properly seated, repair or replace as required.

  • Page 180: Communication Display Module (Cdm)

    Func4 - Last charge termination type (1 = Incomplete, 2 = DVDT, 4 = Normal, 8 = Max. timer). POWER Club Car PART #17075 1. Low Battery 2. Display Window 3. Function Button Figure 12-20 CDM The CDM can be used to retrieve from the onboard computer four important items of information that can be useful in troubleshooting the Excel System vehicle.

  • Page 181: Using The Cdm To Retrieve Data From The Onboard Computer

    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. 2008 Electric Precedent Maintenance and Service Manual Page 12-39...
  • Page 182 CDM Troubleshooting Guide EXCEL SYSTEM TROUBLESHOOTING OBC Will Not Communicate With The CDM CDM battery Failed CDM unit Failed OBC is discharged Replace CDM battery Replace CDM Replace OBC Failed Dash Light Replace Dash Light OBC program is "locked-up" OBC is in a Batteries discharged powerdown mode Remove "+"...

  • Page 183: Section 13 - Iq Display Module (Iqdm) And Iqdm-Pdiagnostics: Iq System

    SECTION 13 — IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. NOTE: For information specific to the IQDM-P handset programming features, see Section 21 — IQ Display Module Programmer (IQDM-P): IQ System .

  • Page 184: Introductory Display

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Introductory Display DIAGNOSTICS: IQ SYSTEM INTRODUCTORY DISPLAY Immediately after the handset is connected to the vehicle, it begins loading the vehicle speed controller information. After a few seconds, the screen displays the following menu items: •...

  • Page 185: Program (Iqdm-P Only)

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM Menu Navigation Figure 13-2 Handset Controls The following menus are accessible on the IQDM handset: PROGRAM (IQDM-P ONLY) The program menu allows the user to view and change custom speed controller settings. See Program Menu on page 21-1.

  • Page 186: Faults

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Monitor Menu DIAGNOSTICS: IQ SYSTEM FAULTS 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 13-7. FUNCTIONS The functions menu allows the user to transfer all current settings from the speed controller to the handset and from the handset to the speed controller.

  • Page 187: Batt Voltage

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM Monitor Menu BATT VOLTAGE Displays the current battery voltage at the speed controller. HEATSINK Displays the temperature (in degrees Celsius) of the speed controller heatsink. During normal operating conditions, the heatsink temperature should be below 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.

  • Page 188: Forward Input

    “private speed mode”. In the event that “private speed mode” is locked out, the controller must be removed and shipped to Club Car before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 21-3.

  • Page 189: Faults Menu

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM 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 displayed often indicate which components in the electrical system need to be tested.
  • Page 190 IQ DISPLAY MODULE (IQDM) AND IQDM-P Faults Menu DIAGNOSTICS: IQ SYSTEM The speed controller, after detecting a fault, will respond in one or more of the following ways: • A. Reduce vehicle speed to zero by reducing armature current • B. Reduce vehicle speed to zero by reducing field current to zero •...

  • Page 191: Hw Failsafe

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM Faults Menu Fault Recovery When a fault is detected by the speed controller, the speed controller will attempt to recover from the fault and resume normal operation. In the case of an intermittent problem such as a loose wiring connection, the controller may be able to recover and operate normally for a while, but the problem should be repaired before placing the vehicle in service.

  • Page 192: Throttle Fault 1

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Faults Menu DIAGNOSTICS: IQ SYSTEM if the vehicle had gone into sleep mode and the accelerator was pressed while the key switch was switched on. The key switch sro fault detect is by default disabled but can be enabled via the program menu KSI SRO ENABLE parameter. 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 1 fault.

  • Page 193: Field Missing

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM Faults Menu FIELD MISSING If the speed controller is operating at a duty cycle of greater than 90% (almost full speed) and the field current is less than 3 amps, a field missing fault is detected by the speed controller. The HPD (High Pedal Detect) fault is detected if the accelerator pedal is already depressed when the key switch is turned to the ON position.

  • Page 194: Open Armature

    The max password tries fault is declared when the incorrect password fault has been declared several times. In the event that the max password tries fault is indicated, the speed controller must be removed and shipped to Club Car before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 21-3. See also Password Tries (IQDM-P only) on page 13-6.

  • Page 195: Functions Menu

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

  • Page 196: Write Settings To Controller

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Functions Menu DIAGNOSTICS: IQ SYSTEM Figure 13-3 Handset Executing Figure 13-4 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 197: Reset All Settings

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM Functions Menu Select write settings to controller. Press + on the change value button to confirm the operation. The handset will display an “executing...” message for the next few seconds while the controller settings are being stored in the handset’s memory (Figure 13-3, Page 13-14).

  • Page 198: Information

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Information DIAGNOSTICS: IQ SYSTEM 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 13-3, Page 13-14). When the handset is finished resetting the speed controller settings, a confirmation message is displayed (Figure 13-6, Page 13-15).

  • Page 199: Faults

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM Programmer Setup FAULTS This menu selection displays faults that have been detected within the handset. This faults menu does not pertain to any faults detected in the speed controller. The following faults can be detected within the handset: CODE NUMBER TEXT DISPLAYED Communication error with controller...

  • Page 200: Iqdm And Iqdm-P Handset Troubleshooting

    IQ DISPLAY MODULE (IQDM) AND IQDM-P IQDM and IQDM-P Handset Troubleshooting DIAGNOSTICS: IQ SYSTEM IQDM AND IQDM-P HANDSET TROUBLESHOOTING In the event that the handset does not function as described in this manual, the following troubleshooting guide should be studied and the referenced test procedures should be performed to troubleshoot the handset. TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES...

  • Page 201: Test Procedures

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM Test Procedures TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Disconnect the IQDM cord from the vehicle. Handset malfunction Wait a few seconds and reconnect the handset to the vehicle Vehicle batteries – loose terminals or corrosion Section 16 —...
  • Page 202 IQ DISPLAY MODULE (IQDM) AND IQDM-P Test Procedures DIAGNOSTICS: IQ SYSTEM The multimeter should indicate continuity on only one pin. If any other reading is obtained, the adaptor must be replaced. Repeat the procedure three more times, each time with the red (+) probe inserted into a different terminal on the end of the adaptor with the square plug.
  • Page 203 IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM Test Procedures 4.3.1. Disconnect the square four-pin connector (3) from the speed controller. 4.3.2. Connect the handset cord to the handset. 4.3.3. Connect the other end of the handset cord (without the adapter) (4) to the four-pin connector of the speed controller (2) (Figure 13-8, Page 13-21).

  • Page 205: Section 14 - Iq Display Module (Iqdm) And Iqdm-Pdiagnostics: Excel System

    SECTION 14 — IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. NOTE: For information specific to the IQDM-P handset programming features, see Section 22 — IQ Display Module Programmer (IQDM-P): Excel System .

  • Page 206: Introductory Display

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Introductory Display DIAGNOSTICS: EXCEL SYSTEM INTRODUCTORY DISPLAY Immediately after the handset is connected to the vehicle, it begins loading the vehicle speed controller information. After a few seconds, the screen displays the following menu items: •...

  • Page 207: Program (Iqdm-P Only)

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM Menu Navigation Figure 14-3 Handset Controls The following menus are accessible on the IQDM handset: PROGRAM (IQDM-P ONLY) The program menu allows the user to view and change custom speed controller settings. See Program Menu on page 22-2.

  • Page 208: Functions

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Monitor Menu DIAGNOSTICS: EXCEL SYSTEM FUNCTIONS The functions menu allows the user to transfer all current settings from the speed controller to the handset and from the handset to the speed controller. See Functions Menu on page 14-13. INFORMATION The information menu displays the model number, serial number, manufacturer date and software version of the speed controller.

  • Page 209: Throttle

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM Monitor Menu THROTTLE Indicates the position of the accelerator pedal from 0% (pedal not pressed) to 95 - 100% (pedal fully pressed). This item can be monitored when the key switch is in the ON or OFF position. BATT AUX VOLTAGE Displays the current battery voltage at the speed controller.

  • Page 210: Speed Pulses

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Monitor Menu DIAGNOSTICS: EXCEL SYSTEM SPEED PULSES The speed pulses menu item displays the activity of the motor speed sensor. With the key switch in the OFF position, the Forward/Reverse switch in the NEUTRAL position, and the vehicle at rest, the handset should should indicate that speed pulses are off.

  • Page 211: Password Tries (Iqdm-P Only)

    “private speed mode”. In the event that “private speed mode” is locked out, the controller must be removed and shipped to Club Car before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 22-4.

  • Page 212: Faults Menu

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Faults Menu DIAGNOSTICS: EXCEL SYSTEM 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 displayed often indicate which components in the electrical system need to be tested.
  • Page 213 IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM Faults Menu The speed controller, after detecting a fault, will respond in one or more of the following ways: • A. Reduce vehicle speed to zero by reducing armature current • B. Reduce vehicle speed to zero by reducing field current to zero •...

  • Page 214: Hw Failsafe

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Faults Menu DIAGNOSTICS: EXCEL SYSTEM Fault Recovery When a fault is detected by the speed controller, the speed controller will attempt to recover from the fault and resume normal operation. In the case of an intermittent problem such as a loose wiring connection, the controller may be able to recover and operate normally for a while, but the problem should be repaired before placing the vehicle in service.

  • Page 215: Speed Sensor

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM Faults Menu SPEED SENSOR If the speed controller does not detect pulses from the speed sensor while the controller outputs power (greater than 75% armature PWM) to the motor, a speed sensor fault is detected. MAIN WELDED If the speed controller detects that the solenoid contacts are welded closed, a main welded fault is detected.

  • Page 216: Low Battery Voltage

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Faults Menu DIAGNOSTICS: EXCEL SYSTEM LOW BATTERY VOLTAGE If the battery voltage falls below 34 volts ±5%, the low battery voltage fault is detected by the speed controller. THERMAL CUTBACK If the controller heatsink temperature is found to be in excess of 85 °C ±5 °C (185 °F ±9 °F) or below –25 °C ±5 °C (–13 °F ±9 °F), the thermal cutback fault is detected.

  • Page 217: Clearing Fault History

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM Functions Menu CLEARING FAULT HISTORY After a repair has been made, the fault history should be cleared. This will enable the trained technician to properly troubleshoot the vehicle in the future, in the event that another problem occurs. It is recommended that the fault history be cleared in order to avoid the replacement of a component that caused a fault in the past, but has been replaced and is now functioning correctly.

  • Page 218: Write Settings To Controller

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Functions Menu DIAGNOSTICS: EXCEL SYSTEM Figure 14-4 Handset Executing Figure 14-5 Confirmation Message WRITE SETTINGS TO CONTROLLER This function transfers all of the speed controller settings (except for “private speed mode”) from the handset to the vehicle speed controller.

  • Page 219: Reset All Settings

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM Functions Menu Select write settings to controller. Press + on the change value button to confirm the operation. The handset will display an “executing...” message for the next few seconds while the controller settings are being stored in the handset’s memory (Figure 14-4, Page 14-14).

  • Page 220: Information

    IQ DISPLAY MODULE (IQDM) AND IQDM-P Information DIAGNOSTICS: EXCEL SYSTEM 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 14-4, Page 14-14). When the handset is finished resetting the speed controller settings, a confirmation message is displayed (Figure 14-7, Page 14-15).

  • Page 221: Faults

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM Programmer Setup FAULTS This menu selection displays faults that have been detected within the handset. This faults menu does not pertain to any faults detected in the speed controller. The following faults can be detected within the handset: CODE NUMBER TEXT DISPLAYED Communication error with controller...

  • Page 222: Iqdm And Iqdm-P Handset Troubleshooting

    IQ DISPLAY MODULE (IQDM) AND IQDM-P IQDM and IQDM-P Handset Troubleshooting DIAGNOSTICS: EXCEL SYSTEM IQDM AND IQDM-P HANDSET TROUBLESHOOTING In the event that the handset does not function as described in this manual, the following troubleshooting guide should be studied and the referenced test procedures should be performed to troubleshoot the handset. TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES...

  • Page 223: Test Procedures

    IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM Test Procedures TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Disconnect the IQDM cord from the vehicle. Handset malfunction Wait a few seconds and reconnect the handset to the vehicle Vehicle batteries – loose terminals or corrosion Section 16 —...
  • Page 224 IQ DISPLAY MODULE (IQDM) AND IQDM-P Test Procedures DIAGNOSTICS: EXCEL SYSTEM The multimeter should indicate continuity on only one pin. If any other reading is obtained, the adaptor must be replaced. Repeat the procedure three more times, each time with the red (+) probe inserted into a different terminal on the end of the adaptor with the square plug.
  • Page 225 IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: EXCEL SYSTEM Test Procedures 4.3.1. Disconnect the square four-pin connector (3) from the speed controller. 4.3.2. Connect the handset cord to the handset. 4.3.3. Connect the other end of the handset cord (without the adapter) (4) to the four-pin connector of the speed controller (2) (Figure 14-9, Page 14-21).

  • Page 227: Section 15 - Electrical Components

    SECTION 15 — ELECTRICAL COMPONENTS DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. KEY SWITCH See General Warnings on page 1-1. TESTING THE KEY SWITCH See Test Procedure 8 – Key Switch and MCOR Limit Switch Circuit on page 11-20 or 12-20. KEY SWITCH REMOVAL Disconnect the battery cables and discharge the controller as instructed.

  • Page 228: Battery Warning Light

    Battery Warning Light ELECTRICAL COMPONENTS 3.3. Secure instrument panel to the dash assembly with three screws (1). Tighten screws to 1.8 ft-lb (2.5 N·m). 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 229: Battery Warning Light Installation

    ELECTRICAL COMPONENTS Forward/Reverse Rocker Switch BATTERY WARNING LIGHT INSTALLATION Install in reverse order of removal. Place the Tow/Run switch in the TOW position and connect the 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 230: Forward/Reverse Rocker Switch Installation

    Forward/Reverse Rocker Switch ELECTRICAL COMPONENTS Figure 15-4 Forward/Reverse Rocker Switch FORWARD/REVERSE ROCKER SWITCH INSTALLATION IQ System: Route the three wires through bezel. Connect the blue (4), red (5) and white (6) wires to the rocker switch (3), exactly as shown in (Figure 15-4, Page 15-4). Excel System: Route the three wires through bezel.

  • Page 231: Electronics Module Cover - Style A Battery Configuration

    ELECTRICAL COMPONENTS Electronics Module Cover – Style A Battery Configuration ELECTRONICS MODULE COVER – STYLE A BATTERY CONFIGURATION See General Warnings on page 1-1. The electronics module cover needs to be removed to gain access to the electronics module, Tow/Run switch, and hour meter.

  • Page 232: Electronics Module Cover - Styleb And C Battery Configurations

    Electronics Module Cover – Style B and C Battery Configurations ELECTRICAL COMPONENTS Figure 15-5 Electronics Module Cover ELECTRONICS MODULE COVER – STYLE B AND C BATTERY CONFIGURATIONS See General Warnings on page 1-1. The electronics module cover needs to be removed to gain access to the speed controller, Tow/Run switch, and onboard computer.

  • Page 233: Tow/Run Switch - Style A Battery Configuration

    ELECTRICAL COMPONENTS Tow/Run Switch – Style A Battery Configuration CAUTION • Exposure to water many damage electronic components. – Do not operate vehicle without this cover properly installed. – Do not direct water stream in the area of the cover. Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first.

  • Page 234: Tow/Run Switch Installation

    Tow/Run Switch – Style B and C Battery Configurations ELECTRICAL COMPONENTS Disconnect the pink wire (3) and blue wire (4) remove switch. TOW/RUN SWITCH INSTALLATION Installation is reverse of removal. Make sure flat on switch is aligned with the flat on bracket. Tighten Tow/Run switch boot/hex nut (1) to 16 in-lb (1.8 N·m) (Figure 15-7, Page 15-8).

  • Page 235: Tow/Run Switch Installation

    ELECTRICAL COMPONENTS Motor Controller Output Regulator (MCOR) TOW/RUN SWITCH INSTALLATION Installation is reverse of removal. Make sure flat on switch is aligned with flat part of D-shaped hole in electronics module (Figure 15-8, Page 15-9). Tighten Tow/Run switch boot/hex nut (1) to 16 in-lb (1.8 N·m). Connect the wires to the switch.

  • Page 236: Mcor Installation

    Reverse Buzzer ELECTRICAL COMPONENTS Figure 15-9 Motor Controller Output Regulator MCOR INSTALLATION Secure the MCOR (2) to the pedal group with two hex-head screws (3) (Figure 15-9, Page 15-10). Tighten screws to 23 in-lb (2.6 N·m). Connect the two-pin and three-pin connectors (1) from the wire harness to the MCOR. Install the pedal group.

  • Page 237: Reverse Buzzer Installation

    ELECTRICAL COMPONENTS Electronics Module – Style A Battery Configuration REVERSE BUZZER INSTALLATION Install the reverse buzzer in the reverse order of removal. Pink wire must be connected to the positive terminal. Tighten screws to 4 in-lb (0.45 N·m). 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 238: Electronics Module Installation

    Electronics Module – Style A Battery Configuration ELECTRICAL COMPONENTS On driver side of the electronic module, separate the 6-pin connector and disconnect all leads to the on-board computer (OBC) (3) and two wires to tow switch. Lift the electronics module from the vehicle. See following WARNING. WARNING •...
  • Page 239 ELECTRICAL COMPONENTS Electronics Module – Style A Battery Configuration A. 16-Pin Connector B. From controller to motor. C. Blue D. Orange E. Yellow F. Green G. White H. Power Connections J. Black K. 4-Pin Connector L. Yellow from Controller M. Orange and Red to OBC N. Black Wire to Controller P. 6-Pin Connector Q. Gray Wire to Charger Receptacle Figure 15-11 Elect-ronics Module Removal –...

  • Page 240: Electronics Module - Style B And C Battery Configurations

    Electronics Module – Style B and C Battery Configurations ELECTRICAL COMPONENTS ELECTRONICS MODULE – STYLE B AND C BATTERY CONFIGURATIONS See General Warnings on page 1-1. While it is not necessary to remove the electronics module from the vehicle, access to individual components may be easier with the module removed.
  • Page 241 ELECTRICAL COMPONENTS Electronics Module – Style B and C Battery Configurations Place the Tow/Run switch in the RUN position. Inspect the vehicle for proper operation. See following WARNINGS. WARNING • Make sure that the vehicle operates in the forward direction when the Forward/Reverse switch is in the FORWARD position.
  • Page 242 Electronics Module – Style B and C Battery Configurations ELECTRICAL COMPONENTS Figure 15-12 Electronics Module Removal – Style B and C Battery Configurations Page 15-16 2008 Electric Precedent Maintenance and Service Manual...

  • Page 243: Speed Controller - Style A Battery Configuration

    ELECTRICAL COMPONENTS Speed Controller – Style A Battery Configuration SPEED CONTROLLER – STYLE A BATTERY CONFIGURATION See General Warnings on page 1-1. TESTING THE SOLID STATE SPEED CONTROLLER See Test Procedure 5 – A1 and A2 Motor Voltage on page 11-18. SPEED CONTROLLER REMOVAL Disconnect the battery cables and discharge the controller as instructed.

  • Page 244: Speed Controller - Style B And C Battery Configurations

    Speed Controller – Style B and C Battery Configurations ELECTRICAL COMPONENTS SPEED CONTROLLER – STYLE B AND C BATTERY CONFIGURATIONS See General Warnings on page 1-1. TESTING THE SOLID STATE SPEED CONTROLLER See Test Procedure 5 – A1 and A2 Motor Voltage on page 12-18. SPEED CONTROLLER REMOVAL Disconnect the battery cables and discharge the controller as instructed.

  • Page 245: Solenoid - Style A Battery Configuration

    ELECTRICAL COMPONENTS Solenoid – Style A Battery Configuration WARNING • Make sure that the vehicle operates in the reverse direction when the Forward/Reverse switch is in the REVERSE position. The reverse buzzer will sound as a warning when the Forward/Reverse switch is in REVERSE.

  • Page 246: Solenoid - Style B And C Battery Configurations

    Solenoid – Style B and C Battery Configurations ELECTRICAL COMPONENTS SOLENOID – STYLE B AND C BATTERY CONFIGURATIONS See General Warnings on page 1-1. The solenoid is located on the rear side of the electronics module. TESTING THE SOLENOID See Test Procedure 3 – Solenoid Activating Coil on page 12-16 and Test Procedure 22 – Solenoid Continuity on page 12-35.

  • Page 247: Onboard Computer (Obc) - Style A Battery Configuration

    ELECTRICAL COMPONENTS Onboard Computer (OBC) – Style A Battery Configuration ONBOARD COMPUTER (OBC) – STYLE A BATTERY CONFIGURATION See General Warnings on page 1-1. TESTING THE ONBOARD COMPUTER See Test Procedure 2 – Onboard Computer Solenoid Lockout Circuit on page 11-15, Test Procedure 18 – Onboard Computer Silicon-Controlled Rectifier (SCR) Circuit on page 11-32, and Test Procedure 19 –...

  • Page 248: Onboard Computer (Obc) - Style B And C Battery Configurations

    Onboard Computer (OBC) – Style B and C Battery Configurations ELECTRICAL COMPONENTS ONBOARD COMPUTER (OBC) – STYLE B AND C BATTERY CONFIGURATIONS See General Warnings on page 1-1. TESTING THE ONBOARD COMPUTER See Test Procedure 2 – Onboard Computer Solenoid Lockout Circuit on page 12-15, Test Procedure 18 – Onboard Computer Silicon-Controlled Rectifier (SCR) Circuit on page 12-32, and Test Procedure 19 –...

  • Page 249: Charger Receptacle

    ELECTRICAL COMPONENTS Charger Receptacle CHARGER RECEPTACLE See General Warnings on page 1-1. 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 electrical contact cleaner.

  • Page 250: Charger Receptacle Installation

    Charger Receptacle ELECTRICAL COMPONENTS Remove the 10-gauge red wire from the positive post of battery no. 1 (Figure 15-13, Page 15-23). Disconnect the black wire from its connector. Disconnect the gray wire from the OBC. Remove the three screws (1) that secure the charger receptacle (2) to the bucket. CHARGER RECEPTACLE INSTALLATION Insert the wires through the hole in the bucket (Figure 15-13, Page 15-23).

  • Page 251: Headlight Adjustment

    ELECTRICAL COMPONENTS Headlight Adjustment HEADLIGHT ADJUSTMENT Headlights are available as an accessory on this vehicle. To raise or lower the headlight beam, washers can be added to the mounting hardware between the headlight and the bumper assembly. See General Warnings on page 1-1. AIMING THE HEADLIGHT BEAM Park the vehicle on a level surface 5 feet away from, and facing a vertical surface such as a garage door or wall.

  • Page 252: Ferrite Beads - Ce Mark Vehicles

    Ferrite Beads – CE Mark Vehicles ELECTRICAL COMPONENTS FERRITE BEADS – CE MARK VEHICLES These beads bring the vehicle into compliance with EMC requirements for use in the European Union. 1. This bead goes around 4 wires (6 Ga. White, 6 Ga. Green, 10 Ga. Orange, 10 Ga. Blue) near the controller. 2.

  • Page 253: Section 16 - Batteries

    SECTION 16 — BATTERIES DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.

  • Page 254: Battery Troubleshooting Chart

    Battery Troubleshooting Chart BATTERIES BATTERY TROUBLESHOOTING CHART V ehicle not operating to expectation. Fully Charge Batteries. Battery Charger T Reading of 6 amps or more. Reading below 6 amps and on-charge voltage above 56 volts. Check electrical system and charger for problems.

  • Page 255: Battery Testing - 12 Volt

    BATTERIES Battery Testing – 12 Volt BATTERY TESTING – 12 VOLT See General Warnings on page 1-1. 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 16-1, Page 16-2).
  • Page 256 Battery Testing – 12 Volt BATTERIES CAUTION • Do not allow battery acid from battery caps or hydrometer to drip onto the front or rear body of the vehicle. Battery acid will cause permanent damage. Wash immediately. Remove the vent cap. Using a battery thermometer (CCI P/N 1011767), record electrolyte temperature of the no.
  • Page 257 BATTERIES Battery Testing – 12 Volt Interpreting the Results of the Hydrometer Test The approximate state of charge can be determined from the following table: APPROXIMATE SPECIFIC GRAVITY (TEMPERATURE CORRECTED) STATE OF CHARGE 1.250-1.280 100% 1.220-1.240 1.190-1.210 1.160-1.180 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.

  • Page 258: Discharge Test

    Battery Testing – 12 Volt BATTERIES DISCHARGE TEST If the previous tests have failed to identify the problem, conduct a discharge test. The discharge test comes closest to simulating actual vehicle operating conditions by continuously drawing current from the batteries until voltage drops to 42.0 volts.
  • Page 259 BATTERIES Battery Testing – 12 Volt Interpreting Discharge Test Results If discharge time is 60 minutes or higher, the problem is not with the batteries. If discharge times are low (less than 60 minutes), replace batteries below 10.05 volts. BATTERY VOLTAGES BATTERY CONDITION 10.50 V 10.50 V...

  • Page 260: Battery Troubleshooting Examples

    Battery Testing – 12 Volt BATTERIES BATTERY TROUBLESHOOTING EXAMPLES The following information represents a few examples of troubleshooting battery problems. Example 1 Vehicle no. 68 was suspected of having a bad battery due to its performance. As a result, the battery charger test was performed.

  • Page 261: Battery Testing - 8 Volt

    BATTERIES Battery Testing – 8 Volt BATTERY TESTING – 8 VOLT See General Warnings on page 1-1. 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 16-1, Page 16-2).
  • Page 262 Battery Testing – 8 Volt BATTERIES CAUTION • Do not allow battery acid from battery caps or hydrometer to drip onto the front or rear body of the vehicle. Battery acid will cause permanent damage. Wash immediately. Remove the vent cap. Using a battery thermometer (CCI P/N 1011767), record electrolyte temperature of the no.
  • Page 263 BATTERIES Battery Testing – 8 Volt Interpreting the Results of the Hydrometer Test The approximate state of charge can be determined from the following table: APPROXIMATE SPECIFIC GRAVITY (TEMPERATURE CORRECTED) STATE OF CHARGE 1.250-1.280 100% 1.220-1.240 1.190-1.210 1.160-1.180 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.

  • Page 264: Discharge Test

    Battery Testing – 8 Volt BATTERIES DISCHARGE TEST If the previous tests have failed to identify the problem, conduct a discharge test. The discharge test comes closest to simulating actual vehicle operating conditions by continuously drawing current from the batteries until voltage drops to 42.0 volts.
  • Page 265 BATTERIES Battery Testing – 8 Volt Interpreting Discharge Test Results If discharge time is 60 minutes or higher, the problem is not with the batteries. If discharge times are low (less than 60 minutes), replace batteries below 6.7 volts. BATTERY VOLTAGES BATTERY CONDITION 7.00 7.00...

  • Page 266: Battery Troubleshooting Examples

    Battery Testing – 8 Volt BATTERIES BATTERY TROUBLESHOOTING EXAMPLES The following information represents a few examples of troubleshooting battery problems. Example 1 Vehicle no. 68 was suspected of having a bad battery due to its performance. As a result, the battery charger test was performed.

  • Page 267: Battery Replacement

    BATTERIES Battery Replacement BATTERY REPLACEMENT See General Warnings on page 1-1. 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 268: Battery Care

    Battery Care BATTERIES (Viewed from driver side of vehicle) (Viewed from driver side of vehicle) 1. RED wire to battery no. 1 (+). 1. RED wire to battery no. 1 (+). 2. BLACK wire to battery no. 6 (-). 2. BLACK wire to battery no. 4 (-). Figure 16-6 Battery Configuration –...

  • Page 269: Battery Care - Vehicles Without The Single-Point Watering System

    BATTERIES Battery Care CAUTION • The watering interval must adequately maintain the electrolyte level above the top of the plates. See Figure 16-8, Page 16-18. • Water the batteries only AFTER charging. Establishing the Watering Interval for New Vehicles If you do not already have a battery watering interval for your vehicles, manually check the battery water level weekly to establish the correct watering interval.

  • Page 270: Self-Discharge

    Battery Care BATTERIES WARNING • If battery wire terminals are damaged or corroded, replace or clean them as necessary. Failure to do so may cause them to overheat during operation and could result in fire, property damage, or personal injury. After use, charge the batteries.

  • Page 271: Mineral Content

    BATTERIES Battery Charger to become permanently inactive. 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. MINERAL CONTENT For the longest battery life, use distilled water in batteries. However, if tap water is to be used, be sure the mineral contents are below these levels: ALLOWABLE CONTENT (PARTS IMPURITY...

  • Page 272: Charging Batteries

    When inserting the DC plug, align the raised guide on the plug with the guide slot in the receptacle and push straight in slowly. Club Car battery chargers interact with the vehicle’s onboard computer. The computer records the amount of energy consumed during vehicle use. While the charger is plugged in, the vehicle’s control circuit is locked out, preventing operation of the vehicle as well as the possibility of consequent damage to the charger and the vehicle.

  • Page 273: Plug And Receptacle

    Batteries should be put on charge even if they have been used for only a short period (10 minutes). The charger is automatic and will turn off when batteries are fully charged. If the charger does not seem to be operating properly, or if the batteries seem weak, contact your local Club Car distributor/dealer. PLUG AND RECEPTACLE The charger cord, plug, and receptacle are wear items and should be inspected daily.

  • Page 274: Early Excessive Discharging

    SINGLE POINT WATERING SYSTEM (SPWS) CAUTION • Water the batteries only AFTER charging. • Use only the equipment provided in the Club Car SPWS Refill Kit (CCI P/N 102958001) to water batteries with the SPWS. Page 16-22 2008 Electric Precedent Maintenance and Service Manual...

  • Page 275: Initial Maintenance Of The Spws

    BATTERIES Single Point Watering System (SPWS) INITIAL MAINTENANCE OF THE SPWS After six-weeks of operation, remove the valves from the batteries and manually check the battery water level to ensure that the SPWS is not leaving any cells dry. This initial electrolyte level check on all the battery cells verifies that all the valves in the SPWS are functioning correctly.
  • Page 276 Single Point Watering System (SPWS) BATTERIES After ensuring adequate water flow rate, press the grey button (7) on the end of the female coupler (8) to disconnect the purger from the pressure regulator. Refilling the Batteries Locate the battery fill coupling (9) on the driver side of the battery compartment, remove the dust cover (10) from the male connector (Figure 16-13, Page 16-24), and connect the hose-end assembly (3) (Figure 16-14, Page 16-24).

  • Page 277: Battery Storage

    BATTERIES Battery Storage BATTERY STORAGE See General Warnings on page 1-1. When storing batteries during the off-season or when maintaining a replacement stock, follow these guidelines: Keep the batteries clean and free of corrosion. See Battery Care on page 16-16. Batteries that are in vehicles for winter storage should be left disconnected in the vehicles if the batteries are not going to be connected to a charger.

  • Page 279: Section 17 - Battery Charger

    SECTION 17 — BATTERY CHARGER Refer to the appropriate battery charger maintenance and service manual. 2008 Electric Precedent Maintenance and Service Manual Page 17-1...

  • Page 281: Section 18 - Motor (Model 5Bc59Jbs6390)

    The vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. The shunt-wound motor is designed for use in IQ and Excel System 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 282 External Motor Testing MOTOR (MODEL 5BC59JBS6390) Using a multimeter set to 200 ohms, place black (–) probe on motor housing. Scratch through paint to ensure a good connection. Place red (+) probe on A1, A2, F1, and F2 terminals respectively (Figure 18-1, Page 18-2). Multimeter should indicate no continuity.

  • Page 283: Motor

    MOTOR (MODEL 5BC59JBS6390) Motor MOTOR See General Warnings on page 1-1. MOTOR REMOVAL Disconnect the battery cables and discharge the controller as instructed. See WARNINGS “To avoid unintentionally starting...” and “After disconnecting the batteries, wait 90 seconds...” in General Warnings on page 1-1. Using two wrenches to prevent posts from turning, disconnect wires from terminals on motor.
  • Page 284 Motor MOTOR (MODEL 5BC59JBS6390) WARNING • Hot! Do not attempt to service hot motor, this could result in severe burns. • Do not position fingers under motor when sliding motor off of the input shaft in step 10. Fingers may get pinched when motor disengages.

  • Page 285: Motor Component Testing And Inspection

    MOTOR (MODEL 5BC59JBS6390) Motor Component Testing and Inspection Figure 18-5 Motor Disassembly Figure 18-6 Brush Spring Removal MOTOR COMPONENT TESTING AND INSPECTION See General Warnings on page 1-1. ARMATURE Visual Inspection Disassemble the motor and carefully inspect the armature for the following characteristics: •...

  • Page 286: Field Windings Inspection

    Motor Component Testing and Inspection MOTOR (MODEL 5BC59JBS6390) A dirty or oily commutator should be cleaned and wiped dry. Abnormalities identified during the inspection can help determine original cause of failure. Slight roughness of the commutator can be polished smooth with 400 grit or finer sandpaper.

  • Page 287: Bearing Inspection

    MOTOR (MODEL 5BC59JBS6390) Motor Component Testing and Inspection CAUTION • When checking brush spring tension, do not over-extend the spring. Using excessive force will damage the spring. NOTE: When installing new brushes, remove and replace brushes one at a time. This method ensures the terminals and brushes will be properly positioned in the rigging.
  • Page 288 Motor Component Testing and Inspection MOTOR (MODEL 5BC59JBS6390) Figure 18-10 Motor Page 18-8 2008 Electric Precedent Maintenance and Service Manual...

  • Page 289: Bearing Removal

    MOTOR (MODEL 5BC59JBS6390) Reconditioning the Motor BEARING REMOVAL Place the wedge attachment tool (2) (CCI P/N 1012812) (Figure 18-11, Page 18-11) between the bearing (15) and the armature (17) (Figure 18-10, Page 18-8). Make sure the wedge attachment tool is supporting the inner race of the bearing.

  • Page 290: Motor Specifications

    Motor Assembly MOTOR (MODEL 5BC59JBS6390) MOTOR SPECIFICATIONS Any rework must be performed by a qualified technician. Motor service specifications are listed in the following table. ITEM SERVICE LIMIT Commutator diameter (minimum) 2.265 in. (66.675 mm) Commutator concentric with armature shaft within 0.001 in.
  • Page 291 MOTOR (MODEL 5BC59JBS6390) Motor Assembly Figure 18-11 Bearing Removal 2.3. Slide the armature, bearing end first, into the stator shell. Make sure the brushes are held back while positioning the armature for proper commutator/brush contact. Release the brushes and place the springs outside the brushes so the brushes are being held against the commutator.

  • Page 292: Motor Installation

    Motor Installation MOTOR (MODEL 5BC59JBS6390) Figure 18-12 Brush Installation Figure 18-13 End Shield Installation MOTOR INSTALLATION See General Warnings on page 1-1. Clean the transaxle input shaft. 1.1. Spray the input shaft thoroughly with CRC ® Brakleen™ or equivalent brake cleaner degreaser. 1.2.
  • Page 293 MOTOR (MODEL 5BC59JBS6390) Motor Installation inch inch 1/8 INCH 3/8 INCH (9.5 MM) (3.1 MM) Figure 18-14 Grease on Putty Knife Figure 18-15 Application of Grease to Input Shaft Grooves 2.6. Check the chamfer (1) and end (2) of the input shaft to ensure these areas are completely clean of grease as shown (Figure 18-16, Page 18-14).
  • Page 294 Motor Installation MOTOR (MODEL 5BC59JBS6390) 1/16 INCH (1.6 MM) Figure 18-16 Clean Chamfer and Input Shaft End Figure 18-17 Gap at Motor and Transaxle 4.2. Loosely install four motor bolts and washers that secure the motor to the transaxle. Do not tighten. 4.3.
  • Page 295 MOTOR (MODEL 5BC59JBS6390) Motor Installation Install the shock absorbers. Tighten nut until rubber bushing expands to the diameter of the cup washer. If removed, install wheels and finger tighten the lug nuts. Lift vehicle and remove jack stands. Lower vehicle to the floor and tighten lug nuts, using a crisscross pattern, to 55 ft-lb (74.6 N·m).

  • Page 296: Motor Speed Sensor

    Motor Speed Sensor MOTOR (MODEL 5BC59JBS6390) MOTOR SPEED SENSOR See General Warnings on page 1-1. TESTING THE MOTOR SPEED SENSOR See Motor Speed Sensor on page 11-33. See Motor Speed Sensor on page 12-33. MOTOR SPEED SENSOR REMOVAL Disconnect the battery cables and discharge the controller as instructed. See WARNINGS “To avoid unintentionally starting...”...
  • Page 297 MOTOR (MODEL 5BC59JBS6390) Motor Speed Sensor Figure 18-20 Motor Speed Sensor 2008 Electric Precedent Maintenance and Service Manual Page 18-17...

  • Page 299: Section 19 - Motor (Model Ej4-4001)

    The vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. The shunt-wound motor is designed for use in IQ and Excel System 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 300: Motor

    Motor MOTOR (MODEL EJ4-4001) With a multimeter set to 200 ohms, place black (–) probe on motor housing. Scratch through paint to ensure a good connection. Place red (+) probe on A1, A2, S1, and S2 terminals respectively. Multimeter should indicate no continuity between the motor housing and all individual terminals.
  • Page 301 MOTOR (MODEL EJ4-4001) Motor WARNING • Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use lifting device to hold vehicle in raised position.

  • Page 302: Motor Disassembly

    Motor MOTOR (MODEL EJ4-4001) CAUTION • Do not position fingers under motor when sliding motor off of the input shaft in step 9. Fingers may get pinched when motor disengages. 10. Carefully slide the motor away from the transaxle until the motor spline disengages the input shaft and remove the motor from the vehicle.
  • Page 303 MOTOR (MODEL EJ4-4001) Motor Orient the motor so that the splined end of the armature is facing down. Inspect the area where the end cap mates with the motor frame. If the end cap appears to be loose where it connects to the motor frame, proceed to step 6;...

  • Page 304: Motor Component Testing And Inspection

    Motor Component Testing and Inspection MOTOR (MODEL EJ4-4001) Figure 19-8 Armature Removal Figure 19-9 A1 and A2 Terminals Figure 19-10 Brush Rigging Figure 19-11 Bearing Retaining Ring MOTOR COMPONENT TESTING AND INSPECTION See General Warnings on page 1-1. ARMATURE INSPECTION AND TESTING Remove the motor from the vehicle.
  • Page 305 MOTOR (MODEL EJ4-4001) Motor Component Testing and Inspection • Flared armature windings • Damaged armature core laminations • Worn, burned or glazed commutators • Dirty or oily commutators • Raised commutator bars • Worn armature bearing or shaft A dirty or oily commutator should be cleaned and wiped dry. Abnormalities identified during the inspection can help determine original cause of failure.

  • Page 306: Motor Frame And Field Windings Inspection

    Motor Component Testing and Inspection MOTOR (MODEL EJ4-4001) MOTOR FRAME AND FIELD WINDINGS INSPECTION Remove the motor from the vehicle. See Motor Removal on page 19-2. Remove the and cap and armature by performing steps 1 through 7 of Motor Disassembly on page 19-4. Burned or scorched insulation on the field windings indicates the motor has overheated due to overloads or grounded or shorted coil windings.
  • Page 307 MOTOR (MODEL EJ4-4001) Motor Component Testing and Inspection Bearing Inspection NOTE: Replacement of the end cap bearing is highly-recommended if the end cap is removed from the motor. The following procedure is provided as a guideline for determining general bearing failure. Remove the motor from the vehicle.
  • Page 308 Motor Component Testing and Inspection MOTOR (MODEL EJ4-4001) Figure 19-15 Motor Page 19-10 2008 Electric Precedent Maintenance and Service Manual...

  • Page 309: Reconditioning The Motor

    MOTOR (MODEL EJ4-4001) Reconditioning the Motor RECONDITIONING THE MOTOR See General Warnings on page 1-1. 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 310 Motor Assembly MOTOR (MODEL EJ4-4001) Figure 19-16 Brush Rigging Figure 19-17 Retracted Brushes Figure 19-18 Armature Installation Figure 19-19 Brush Setting 2.5. One at a time, push the brushes back until they are completely retracted into their mounting slots and the spring pressure holds them in the retracted position as shown (Figure 19-17, Page 19-12).

  • Page 311: Motor Installation

    MOTOR (MODEL EJ4-4001) Motor Installation Make sure the armature turns freely. If it does not turn freely, disassemble the motor to find the problem. MOTOR INSTALLATION See General Warnings on page 1-1. Clean the transaxle input shaft. 1.1. Spray the input shaft thoroughly with CRC ®...
  • Page 312 Motor Installation MOTOR (MODEL EJ4-4001) 4.1. Slide the motor coupling onto the transaxle input shaft. See following NOTE. NOTE: The coupling will push any excess grease on the input shaft along the shaft toward the transaxle. When the motor is pushed onto the input shaft, the motor housing will not bottom out against the transaxle housing (Figure 19-15, Page 19-10).
  • Page 313 MOTOR (MODEL EJ4-4001) Motor Installation 4.9. Secure the white, orange, green, and blue wires with a wire tie so that none of the motor wires will scrub the motor or transaxle when the vehicle is in operation. 4.10.Connect the three-pin speed sensor wire to the vehicle wire harness. If using a chain hoist, lower the vehicle and guide the leaf springs into the shackles.

  • Page 315: Section 20 - Transaxle (Type G)

    SECTION 20 — TRANSAXLE (TYPE G) DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. LUBRICATION See General Warnings on page 1-1. 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 20-5, Page 20-3).
  • Page 316 Axle Bearing and Shaft TRANSAXLE (TYPE G) CAUTION • Do not scar or damage the inside surfaces of the tube when removing the oil seal and adapter ring. A damaged tube might have to be replaced. NOTE: Do not discard the adapter ring. If the adapter ring is lost or damaged, the axle tube will have to be replaced. Varying rear axle configurations have been installed on vehicles.
  • Page 317 TRANSAXLE (TYPE G) Axle Bearing and Shaft Figure 20-5 Transaxle – Type G 2008 Electric Precedent Maintenance and Service Manual Page 20-3...

  • Page 318: Axle Bearing

    Axle Bearing and Shaft TRANSAXLE (TYPE G) Axle Shaft and Oil Seal Installation If previously removed, install a new oil seal. 1.1. Clean seal seat in the adapter ring (39) (Figure 20-3, Page 20-2). 1.2. Place a new seal (15) in the adapter ring with the seal lip facing toward the adapter ring lip (Figure 20-3, Page 20-2).

  • Page 319: Transaxle

    TRANSAXLE (TYPE G) Transaxle TRANSAXLE See General Warnings on page 1-1. TRANSAXLE REMOVAL Disconnect the battery cables and discharge the controller as instructed. See WARNINGS “To avoid unintentionally starting...” and “After disconnecting the batteries, wait 90 seconds...” in General Warnings on page 1-1. Place chocks at the front wheels and slightly loosen lug nuts on both rear wheels.
  • Page 320 Transaxle TRANSAXLE (TYPE G) CAUTION • Do not position fingers under motor when sliding motor off of the input shaft. Fingers may get pinched when motor disengages. Figure 20-8 Disconnect Shocks Figure 20-9 Shackles 11. Carefully remove the motor from the transaxle. Slide the motor away from the transaxle until the motor spline becomes disengaged from the input shaft, then lift motor out.
  • Page 321 TRANSAXLE (TYPE G) Transaxle 1. Precedent 2. Villager 4 Figure 20-10 Leaf Springs Figure 20-11 Motor Mounting Bolts Figure 20-12 Motor Positioning Bolt – EJ4–4001 and 5BC59JBS6390 Motors Only 2008 Electric Precedent Maintenance and Service Manual Page 20-7...

  • Page 322: Transaxle Disassembly, Inspection, And Assembly

    Transaxle Disassembly, Inspection, and Assembly TRANSAXLE (TYPE G) TRANSAXLE DISASSEMBLY, INSPECTION, AND ASSEMBLY See General Warnings on page 1-1. TRANSAXLE DISASSEMBLY AND INSPECTION To detach axle tubes (14 and 35) from the transaxle housing, remove the bolts (8) (Figure 20-5, Page 20-3). Remove 11 bolts (24) that hold housing together.
  • Page 323 TRANSAXLE (TYPE G) Transaxle Disassembly, Inspection, and Assembly Disassemble the differential gear case: 8.1. Remove the hex bolts (33) and the ring gear (32) from the differential case (Figure 20-5, Page 20-3). 8.2. Remove the ring gear. 8.3. Separate the differential gear case housing. If necessary, install two of the hex bolts (removed previously in step 8.1.) into the differential gear unit and, while holding the unit slightly above the work area, lightly tap the bolt heads (Figure 20-14, Page 20-9).

  • Page 324: Transaxle Assembly

    Transaxle Disassembly, Inspection, and Assembly TRANSAXLE (TYPE G) TRANSAXLE ASSEMBLY CAUTION • Do not press against the bearing outer race. • The housing and all parts must be wiped clean and dry before reassembly. If bearings (13) were removed during disassembly, install new bearings using an arbor press (Figure 20-5, Page 20-3).

  • Page 325: Transaxle Installation

    TRANSAXLE (TYPE G) Transaxle Installation WARNING • Be sure retaining ring is properly seated in its groove. If ring is not properly installed, the axle assembly will separate from the transaxle and damage the axle assembly and other components. Loss of vehicle control could result in severe personal injury or death.
  • Page 326 Transaxle Installation TRANSAXLE (TYPE G) WARNING • Make sure that the vehicle operates in the forward direction when the Forward/Reverse switch is in the FORWARD position. • Make sure that the vehicle operates in the reverse direction when the Forward/Reverse switch is in the REVERSE position.

  • Page 327: Section 21 - Iq Display Module Programmer (Iqdm-P): Iq System

    SECTION 21 — IQ DISPLAY MODULE PROGRAMMER (IQDM-P): IQ SYSTEM DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. NOTE: For information pertaining to the introductory display, menu navigation, and monitor, faults and function menus, see Section 13 —...

  • Page 328: Speed Setting

    IQ DISPLAY MODULE PROGRAMMER Program Menu (IQDM-P): IQ SYSTEM Figure 21-2 Access Program Menu Figure 21-3 Change Speed Setting SPEED SETTING The vehicle’s top speed can be changed by selecting values 1 through 3 (Figure 21-3, Page 21-2). If a value of 4 is displayed for the speed setting, a special access code has been entered to place the vehicle in “private speed mode.”...

  • Page 329: Fast Accel

    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. SLOW PEDAL UP slow pedal up is an option that toggles either on or off.

  • Page 330: Ksi Sro Enable

    IQ DISPLAY MODULE PROGRAMMER Program Menu (IQDM-P): IQ SYSTEM KSI SRO ENABLE The ksi sro enable (key switch static return to off) option toggles either on or off. With this menu item enabled, the vehicle will not operate if the key switch is on after the car is charged or the run/tow switch is cycled. The vehicle will be disabled when the controller is powered up with the key switch on and after any of the following events have occured: 1.

  • Page 331: Section 22 - Iq Display Module Programmer (Iqdm-P): Excel System

    SECTION 22 — IQ DISPLAY MODULE PROGRAMMER (IQDM-P): EXCEL SYSTEM DANGER • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. NOTE: For information pertaining to the introductory display, menu navigation, and monitor, faults and function menus, see Section 14 —...

  • Page 332: Program Menu

    IQ DISPLAY MODULE PROGRAMMER Program Menu (IQDM-P): EXCEL SYSTEM PROGRAM MENU The program menu can be accessed by pressing the right arrow on the navigation button when the square beside program is blinking (Figure 22-3, Page 22-2). When the program menu is active, use the up or down arrows on the navigation button to go to the desired item in the program menu.

  • Page 333: Speed Setting

    IQ DISPLAY MODULE PROGRAMMER (IQDM-P): EXCEL SYSTEM Program Menu SPEED SETTING The vehicle’s top speed can be changed by selecting values 1 through 3 (Figure 22-4, Page 22-2). If a value of 4 is displayed for the speed setting, a special access code has been entered to place the vehicle in “private speed mode.” A speed setting of 4 cannot be selected with the speed setting menu item.

  • Page 334: S3 Fwd Speed

    ANSI Z130.1 – American National Standard for Golf Cars – Safety and Performance Specifications because it is capable of speeds in excess of 15 mph (24.1 km/h). For more information on this feature, contact your local Club Car distributor or dealer. VEHICLE S/N Six digit number programmed by vehicle manufacturer.
  • Page 335 INDEX see also repair, front and rear body ...... 4-3 body, rear accelerator return spring ......... 5-4 removal ............4-10 access panel ..........4-11, 4-16 see also repair, front and rear body ... 4-10, armature, motor 4-14 see motor, armature ........18-5, 19-6 brake return spring..........
  • Page 336 INDEX installation ........... 4-6–4-7 removal ............4-5–4-6 DANGER IQ Display Module (IQDM) definition of ............1-1 Excel system debris shields ............5-3 diagnostics ............ 14-1 diode, solenoid IQ system testing ..........11-16, 12-16 diagnostics ............ 13-1 drive motor IQ Display Module Programming (IQDM-P) see motor ..........18-3, 19-2 Excel system.............
  • Page 337 INDEX speed setting ..........22-3 brush vehicle decal..........22-4 inspection............19-8 vehicle s/n ............. 22-4 brush spring IQ system inspection............19-8 Code A, Code B, and Code C ......21-3 component Fast Accel ............. 21-3 inspection............18-6 handset ............21-1 disassembly..........18-4, 19-4 KSI SRO Enable ..........
  • Page 338 INDEX installation ............7-8 connector, 16-pin removal .............. 7-4 see test procedures......11-22, 12-22 rear beauty panel installation ..........15-17–15-18 installation ..........4-11, 4-16 removal ..........15-17–15-18 removal ............ 4-11, 4-16 speed sensor rear body see motor, speed sensor........18-16 see body, rear ...........4-10, 4-14 steering rear body, four-passenger ........
  • Page 339 INDEX battery troubleshooting examples ....16-8, 16-14 test procedures communication display module (CDM)... 11- 16-pin connector ........11-22, 12-22 39, 12-39 batteries/voltage check ......11-14, 12-14 IQDM and IQDM-P handset ....13-18, 14-18 battery pack voltage (under load) .....11-19, troubleshooting guide 1......11-8, 12-7 12-20 troubleshooting guide 2......11-11, 12-11 battery warning light ......
  • Page 342 1. Ease of Understanding 2. Ease of Finding Information 3. Clarity of Illustrations Comments/Suggestions Please fax a copy of this page to (706) 228-2662. T hank Y ou! Club Car Technical Publication Department 2008 Electric Precedent Maintenance and Service Manual...

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