Club Car Precedent 2004 Maintenance And Service
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Club Car Precedent 2004 Maintenance And Service

Iq system electric vehicles
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Maintenance
2004
And
Service
IQ System
Electric Vehicles
Manual No. 102397619
Edition Code 1203D0205C

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Summary of Contents for Club Car Precedent 2004

  • Page 1 Maintenance 2004 Service IQ System Electric Vehicles Manual No. 102397619 Edition Code 1203D0205C...
  • 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 knowl- edge and facilities so they can provide prompt and efficient service for vehicle owners. Regional technical rep- resentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and other service publications also represent Club Car’s continuing commitment to customer support.
  • Page 4 NOTE: This manual represents the most current information at the time of publication. Club Car, Inc. is continually working to further improve our vehicles and other products. These improvements may affect servicing procedures.

  • Page 5: Table Of Contents

    CONTENTS SECTION 1 – SAFETY General Warnings ..........................SECTION 2 – VEHICLE SPECIFICATIONS SECTION 3 – GENERAL INFORMATION Serial Number Identification ......................Safety Committee ..........................Storage ............................. Preparing the Electric Vehicle for Extended Off-Season Storage ..........Returning the Stored Electric Vehicle to Service ................SECTION 4 –...
  • Page 6 Dash Assembly ..........................4-14 Dash Assembly Removal ......................4-14 Dash Assembly Installation ......................4-15 SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group ............................. Pedal Group Removal ........................MCOR ............................Debris Shields ..........................Brake Return Spring ........................Pawl Assembly ..........................Accelerator Return Spring ......................
  • Page 7 Front Suspension Components ......................7-12 Tie Rod End Removal ........................7-12 Tie Rod Installation ........................7-12 Leaf Spring Removal ........................7-13 Leaf Spring Installation ......................... 7-13 Kingpin and Steering Spindle Removal ..................7-13 Kingpin and Steering Spindle Installation ..................7-13 Control Arm Removal ........................
  • Page 8 Periodic Lubrication Schedule ......................10-4 SECTION 11 – ELECTRICAL SYSTEM AND TESTING General Information ......................... 11-1 Electrical Circuits ..........................11-3 Control Circuit ..........................11-3 Onboard Computer Circuit ......................11-3 Power Circuit ..........................11-9 Charge Circuit ..........................11-10 Wiring Diagram ..........................11-11 Troubleshooting ..........................
  • Page 9 Battery Care ............................13-4 Preventive Maintenance ....................... 13-4 Self-Discharge ..........................13-5 Electrolyte Level ........................... 13-5 Mineral Content ..........................13-6 Vibration Damage ......................... 13-6 Battery Charging ..........................13-6 Charger Shuts Off After 16 Hours ....................13-7 Deep-Discharge ..........................13-7 Early Excessive Discharging ......................13-7 Incoming AC Service ........................
  • Page 10 Motor Assembly ..........................15-10 Motor Installation ..........................15-12 Motor Speed Sensor ........................15-15 SECTION 16A – TRANSAXLE (TYPE G) Transaxle Identification ........................16a-1 Lubrication ............................16a-1 Axle Bearing and Shaft ........................16a-1 Axle Shaft ............................. 16a-1 Axle Bearing ..........................16a-5 Transaxle ............................

  • Page 11: 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 12 SAFETY General Warnings ∆ 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 13: Section 2 - Vehicle Specifications

    SECTION 2 – VEHICLE SPECIFICATIONS Two- Four- Passenger Passenger 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 15: Section 3 - General Information

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

  • Page 16: 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 17: Returning The Stored Electric Vehicle To Service

    GENERAL INFORMATION Storage 2. Batteries should be clean and free of corrosion. Wash tops and terminals of batteries with a solution of baking soda and water (1 cup (237 mL) baking soda per 1 gallon (3.8 L) of water). Rinse solution off bat- teries.

  • Page 19: 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 20: Front And Rear Body Repair

    BODY AND TRIM Front and Rear Body Repair CAUTION • To prevent damage to the vehicle when removing difficult stains or heavy soiling, remove the seat bottom from the vehicle first. FRONT AND REAR BODY REPAIR See General Warnings, Section 1, Page 1-1. STRESS LINES OR STREAKS Repeatedly flexing the Surlyn body can cause white stress lines or streaks in the finish.

  • Page 21: Front Body

    BODY AND TRIM Front Body FRONT BODY See General Warnings, Section 1, Page 1-1. FRONT BODY REMOVAL 1. Remove the four screws (2) and pull the brow cap (1) from the brow and fascia assembly (4) (Figure 4-1, Page 4-4). 2.
  • Page 22 BODY AND TRIM Front Body TYPICAL 4 PLACES TYPICAL 5 PLACES TYPICAL 5 PLACES Figure 4-1 Front Body Page 4-4 2004 Precedent IQ System Golf Car Maintenance and Service Manual...

  • Page 23: Front Bumper

    BODY AND TRIM Front Bumper Front Body Installation, Continued: 3. Install front beauty panel (3) over brow (5). Tabs on the forward edge of the front beauty panel should fit into slots between the fascia and the brow. 4. Position brow cap (1) to cover the edge of both the brow (5) and the front beauty panel (3). Secure brow cap (1) with four screws (2).

  • Page 24: Floor Mat And Retainers

    BODY AND TRIM Floor Mat and Retainers FLOOR MAT AND RETAINERS See General Warnings, Section 1, 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) can be loosened slightly to allow the floor mat to be slid from beneath the retainers (1) (Figure 4-3, Page 4-6).

  • Page 25: Kick Plate And Charger Bezel

    BODY AND TRIM Kick Plate and Charger Bezel KICK PLATE AND CHARGER BEZEL See General Warnings, Section 1, Page 1-1. KICK PLATE AND CHARGER BEZEL REMOVAL 1. If charger bezel (4) requires removal, use charger bezel tool (CCI P/N 102562401) to remove bezel from the kick plate (Figure 4-4, Page 4-8).

  • Page 26: Rear Body

    BODY AND TRIM Rear Body Figure 4-4 Kick Plate REAR BODY See General Warnings, Section 1, Page 1-1. UNIVERSAL ACCESSORY MOUNTING The Structural Accessory Module (SAM) includes two threaded inserts on both the driver side and the pas- senger side (Figure 4-5, Page 4-9). These inserts serve as common attachment points for various accessor- ries.

  • Page 27: Backrest And Structural Accessory Module

    BODY AND TRIM Rear Body ATTACHMENT POINTS Figure 4-5 Universal Accessory Mounting BACKREST AND STRUCTURAL ACCESSORY MODULE SAM Removal 1. If the vehicle has a canopy, the rear upright supports must be removed from the SAM. 2. Remove four bolts (4) to release the SAM (3) from the vehicle (Figure 4-6, Page 4-10) SAM Installation 1.
  • Page 28 BODY AND TRIM Rear Body TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES Figure 4-6 Backrest and SAM Disassembly Page 4-10 2004 Precedent IQ System Golf Car Maintenance and Service Manual...

  • Page 29: Rear Body Components Removal

    BODY AND TRIM Rear Body REAR BODY COMPONENTS REMOVAL Rear Beauty Panel Removal 1. Remove SAM. See SAM Removal on page 4-9. 2. Remove one screw (3) from each canopy support bracket (1 and 2) (Figure 4-7, Page 4-13). Remove canopy supports.
  • Page 30 BODY AND TRIM Rear Body Rear Underbody Installation 1. Install rear underbody (4) on the vehicle (Figure 4-7, Page 4-13). Install two screws (18) to secure the underbody to the two wheel liners (8 and 9) and install four screws (5) to secure the underbody to its vehi- cle.
  • Page 31 BODY AND TRIM Rear Body TYPICAL 4 PLACES WHITE BLUE BODY CLIPS Figure 4-7 Rear Body Disassembly 2004 Precedent IQ System Golf Car Maintenance and Service Manual Page 4-13...

  • Page 32: Dash Assembly

    BODY AND TRIM Dash Assembly DASH ASSEMBLY See General Warnings, Section 1, Page 1-1. DASH ASSEMBLY REMOVAL 1. Remove two screws (5) at sides and one screw (4) on top of instrument panel (3) (Figure 4-8, Page 4-14). 2. Tilt instrument panel up to release it from the dash assembly (1). 3.

  • Page 33: Dash Assembly Installation

    BODY AND TRIM Dash Assembly DASH ASSEMBLY INSTALLATION 1. 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 4-8, Page 4-14). Tighten screws to 8.8 ft-lb (12 N·m).

  • Page 35: Section 5 - Accelerator And Brake Pedal Group

    SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP ∆ DANGER • See General Warnings, Section 1, Page 1-1. ∆ WARNING • See General Warnings, Section 1, Page 1-1. PEDAL GROUP See General Warnings, Section 1, Page 1-1. PEDAL GROUP REMOVAL 1.
  • Page 36 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group TYPICAL 2 PLACES TYPICAL 2 PLACES ELECTRICAL CONNECTIONS Figure 5-2 Pedal Group Page 5-2 2004 Precedent IQ System Golf Car Maintenance and Service Manual...

  • Page 37: Mcor

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Pedal Group Removal, Continued: 6. Loosen turnbuckle (6) until the threaded rod from the pedal group is free of the turnbuckle. 7. Remove two screws (2) on the driver side of the pedal group and two screws (1) on the passenger side of the pedal group.

  • Page 38: Pawl Assembly

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group PAWL ASSEMBLY The pawl assembly (6) serves to lock the brakes when the PARK pedal is pressed. The pawl assembly also releases the brakes when either the STOP or GO pedal is pressed (Figure 5-4, Page 5-5). The pawl assem- bly is serviced as a unit.
  • Page 39 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group OPPOSITE SIDE VIEW Typical 3 places Figure 5-4 Brake Pedal 2004 Precedent IQ System Golf Car Maintenance and Service Manual Page 5-5...

  • Page 40: Pedal Group Installation

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Figure 5-5 Accelerator Spring Clip Figure 5-6 Accelerator Spring Upper Crosspin Figure 5-7 Accelerator Spring Pin Removal PEDAL GROUP INSTALLATION 1. 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).
  • Page 41 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group 7. Install the floor mat (2) over the pedal group. Make sure tabs on floor mat sides are beneath the sill (3). Tighten screws (1) to 53 in-lb (6 N·m) (Figure 5-1, Page 5-1). 2004 Precedent IQ System Golf Car Maintenance and Service Manual Page 5-7...

  • Page 43: Section 6 - Wheel Brake Assemblies

    SECTION 6 – WHEEL BRAKE ASSEMBLIES ∆ DANGER • See General Warnings, Section 1, Page 1-1. ∆ WARNING • See General Warnings, Section 1, Page 1-1. • Some aftermarket brake shoes contain asbestos fiber, and asbestos dust is created when these brake mechanisms are handled.
  • Page 44 WHEEL BRAKE ASSEMBLIES Brake Shoe Removal Brake Shoe Removal, Continued: 7. 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. BRAKE CABLES BRAKE...
  • Page 45 WHEEL BRAKE ASSEMBLIES Brake Shoe Removal TYPICAL 4 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 6-4 Self-adjusting Wheel Brake Assembly 2004 Precedent IQ System Golf Car Maintenance and Service Manual Page 6-3...
  • Page 46 WHEEL BRAKE ASSEMBLIES Brake Shoe Removal Brake Shoe Removal, Continued: 9. 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.

  • Page 47: Brake Assembly Cleaning

    WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning BRAKE ASSEMBLY CLEANING See General Warnings, Section 1, Page 1-1. See also Warning on Page 6-1. 1. Carefully clean the brake backing plate and all of its mechanical components. 2. Remove the rubber boot from backing plate and wipe with a clean damp cloth. 3.

  • Page 48: Brake Shoe Installation

    WHEEL BRAKE ASSEMBLIES Brake Shoe Installation 17T STAMPING ON TRAILING SHOE Figure 6-11 Apply Grease To Brake Adjuster Figure 6-12 Install Adjuster Wheel, Trailing Shoe BRAKE SHOE INSTALLATION See General Warnings, Section 1, Page 1-1. See also Warning on Page 6-1. 1.
  • Page 49 WHEEL BRAKE ASSEMBLIES Brake Shoe Installation 4. While maintaining spring attachment on both shoes, position tips of leading shoe in the mounting slots and then push shoe into place. Hold shoe in position and install retaining clip (Figure 6-15, Page 6-7). 5.

  • Page 50: Brake Cable Equalizer Adjustment

    WHEEL BRAKE ASSEMBLIES Brake Cable Equalizer Adjustment Brake Shoe Installation, Continued: 7.2. Using 90° internal snap ring pliers (0.090 tip) (CCI P/N 1012560), attach the internal retaining ring into the axle tube hub so that it seats against the axle bearing assembly and into the machined slot in the inside wall of the axle tube hub (Figure 6-3, Page 6-2).

  • Page 51: Brake Cluster Removal And Installation

    WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation JAM NUT (1 OF 2) EQUALIZER TURNBUCKLE Figure 6-18 Brake Adjustment BRAKE CLUSTER REMOVAL AND INSTALLATION See General Warnings, Section 1, Page 1-1. See also Warning on Page 6-1. Brake Cluster Removal 1.

  • Page 52: Brake Cluster Installation

    WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation Brake Cluster Removal, Continued: 9. Remove four bolts (11) and lock nuts (10) that mount the brake assembly to the transaxle (Figure 6-4, Page 6-3). 10. Remove brake assembly from transaxle. BRAKE CLUSTER INSTALLATION 1.

  • Page 53: Brake Cable Removal And Installation

    WHEEL BRAKE ASSEMBLIES Brake Cable Removal and Installation BRAKE CABLE REMOVAL AND INSTALLATION See General Warnings, Section 1, Page 1-1. See also Warning on Page 6-1. Brake Cable Removal 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warnings, Section 1, Page 1-2.
  • Page 54 WHEEL BRAKE ASSEMBLIES Brake Cable Removal and Installation AS SEEN FROM DRIVER-SIDE OF VEHICLE REAR OF VEHICLE Figure 6-20 Disconnect Cables at Rear Brakes Figure 6-21 Brake Cable Mounting Tab Brake Cable Installation NOTE: The driver-side and passenger-side brake cables are not interchangeable. The driver-side cable is shorter than the passenger-side cable.

  • Page 55: Section 7 - Steering And Front Suspension

    SECTION 7 – STEERING AND FRONT SUSPENSION ∆ DANGER • See General Warnings, Section 1, Page 1-1. ∆ WARNING • See General Warnings, Section 1, 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 56: Steering Wheel Installation

    STEERING AND FRONT SUSPENSION Steering Column Steering Wheel Removal, Continued: 5.6. Remove the steering wheel bolt (6) and the steering wheel (7) from the steering column (9) (Figure 7-3, Page 7-3). Figure 7-1 Steering Wheel Puller 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 57 STEERING AND FRONT SUSPENSION Steering Column Figure 7-3 Steering Column 2004 Precedent IQ System Golf Car Maintenance and Service Manual Page 7-3...

  • Page 58: Steering Column Installation

    STEERING AND FRONT SUSPENSION Rack and Pinion Steering Column Removal, Continued: 4. Loosen the bolt (11), that attaches the steering column universal joint to the stud on the steering gear (Figure 7-3, Page 7-3). 5. Remove the four bolts (10) that attach the steering column to the frame. 6.

  • Page 59: Rack And Pinion Disassembly

    STEERING AND FRONT SUSPENSION Rack and Pinion Figure 7-4 Rack and Pinion Removal 4. Remove the three bolts (5) from the steering rack and pinion assembly mounting bracket. 5. Remove the bolt (7) from the universal joint, then remove the rack and pinion assembly and universal joint from the vehicle.
  • Page 60 STEERING AND FRONT SUSPENSION Rack and Pinion Figure 7-5 Steering Gear Page 7-6 2004 Precedent IQ System Golf Car Maintenance and Service Manual...
  • Page 61 STEERING AND FRONT SUSPENSION Rack and Pinion Rack and Pinion Disassembly, Continued: 10. If the ball bearing (4) (Figure 7-5, Page 7-6) has been damaged, remove the c-type stop ring (3) and press the bearing off (Figure 7-9, Page 7-7). 11.

  • Page 62: Rack And Pinion Assembly

    STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION ASSEMBLY 1. 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). CAUTION •...

  • Page 63: Rack And Pinion Installation

    STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION INSTALLATION 1. To minimize corrosion, apply a light coat of anti-seize lubricating compound to the splined portion of the steering column universal joint. 2. Align the flat portion of the shaft (13) spline with the bolt hole in the upper universal joint and then slide the shaft into the universal joint.

  • Page 64: Front Suspension

    STEERING AND FRONT SUSPENSION Front Suspension FRONT SUSPENSION See General Warnings, Section 1, 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, Section 10, Page 10-4.. CAUTION •...
  • Page 65 STEERING AND FRONT SUSPENSION Front Suspension 7 MM DEEP WELL SOCKET Figure 7-14 Check Camber Figure 7-15 Adjust Camber Toe-in Adjustment 1. On a level surface, roll the vehicle forward, then stop. Make sure the front wheels are pointed straight ahead.

  • Page 66: Front Suspension Components

    STEERING AND FRONT SUSPENSION Front Suspension Components Toe-in Adjustment, Continued: 5. Subtract the measurement on the front of the tires from the measurement on the rear of the tires. The dif- ference is the toe-in. Proper toe-in is 5/16 inch (7.8 mm). 6.

  • Page 67: Leaf Spring Removal

    STEERING AND FRONT SUSPENSION Front Suspension Components LEAF SPRING REMOVAL 1. Loosen lug nuts on both front wheels and raise front of vehicle with a chain hoist or floor jack. Place jack stands under the aluminum rails of the vehicle frame just aft of the front suspension. Lower the vehicle onto the jack stands.

  • Page 68: Control Arm Removal

    STEERING AND FRONT SUSPENSION Front Suspension Components Kingpin and Steering Spindle Installation, Continued: 5. Attach the tie rod ends (12) to the spindle tabs, install and tighten the nuts (14) to 70 ft-lb (95 N·m). Install the retaining pins (15) (Figure 7-18, Page 7-15). 6.
  • Page 69 STEERING AND FRONT SUSPENSION Front Suspension Components Figure 7-18 Upper Front Suspension Assembly 2004 Precedent IQ System Golf Car Maintenance and Service Manual Page 7-15...
  • Page 70 STEERING AND FRONT SUSPENSION Front Suspension Components CLEVIS Figure 7-19 Lower Front Suspension Assembly Page 7-16 2004 Precedent IQ System Golf Car Maintenance and Service Manual...

  • Page 71: Control Arm Installation

    STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs CONTROL ARM INSTALLATION 1. Install the control arm in reverse order of removal. Tighten the control arm bolts (11 and 19) to 20 ft-lb (27 N·m) (Figure 7-18, Page 7-15). Tighten three rack and pinion mounting bolts (17) to 22 ft-lb (30 N·m) 2.

  • Page 72: Hub Installation

    HUB INSTALLATION 1. Clean and apply a light coat of anti-seize lubricant to the spindle shaft (3). 2. Slide the hub assembly (9) onto the spindle shaft (Figure 7-19, Page 7-16). 3. Install a new flanged lock nut (11) and tighten to 36 ft-lb (50 N·m). 4.

  • Page 73: Section 8 - Wheels And Tires

    SECTION 8 – WHEELS AND TIRES ∆ DANGER • See General Warnings, Section 1, Page 1-1. ∆ WARNING • See General Warnings, Section 1, Page 1-1. GENERAL INFORMATION Maximum tire life and good vehicle handling qualities are directly related to proper wheel and tire care. •...

  • Page 74: Tire Removal

    Small holes in the casing can be plugged using a standard automotive tubeless tire repair kit avail- able at your local Club Car dealer. Page 8-2 2004 Precedent IQ System Golf Car Maintenance and Service Manual...

  • Page 75: Tire Installation

    WHEELS AND TIRES Tires 2. 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. TIRE INSTALLATION ∆ WARNING • While mounting or inflating tire, keep hands, fingers, etc. from exposed areas between the tire bead and rim.
  • Page 76 WHEELS AND TIRES Tires Tire Installation, Continued: 7. Quickly remove the air nozzle and install the valve core. 8. Adjust air pressure in tire to recommended pressure. See Section 2 – Vehicle Specifications. 9. Immerse the wheel and tire assembly in water to make sure there are no leaks. Page 8-4 2004 Precedent IQ System Golf Car Maintenance and Service Manual...

  • Page 77: Section 9 - Rear Suspension

    SECTION 9 – REAR SUSPENSION ∆ DANGER • See General Warnings, Section 1, Page 1-1. ∆ WARNING • See General Warnings, Section 1, Page 1-1. GENERAL INFORMATION The rear suspension of the Precedent vehicle is completely independent. It consists of two leaf springs con- trolled by two shock absorbers mounted between the springs and the vehicle frame.
  • Page 78 REAR SUSPENSION Leaf Springs BRAKE CABLE HANGER MOUNTING TYPICAL ON EACH SIDE OF VEHICLE TYPICAL 2 PLACES Figure 9-1 Rear Suspension Assembly and Mounting Page 9-2 2004 Precedent IQ System Golf Car Maintenance and Service Manual...
  • Page 79 REAR SUSPENSION Leaf Springs Leaf Spring Removal, Continued: ∆ 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 80: Leaf Spring Installation

    REAR SUSPENSION Leaf Springs LEAF SPRING INSTALLATION 1. 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. 2.

  • Page 81: Section 10 - Periodic Maintenance

    Any vehicle not functioning correctly should be removed from use until it is properly repaired. This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service. PRE-OPERATION AND DAILY SAFETY CHECKLIST Use the following checklist as a guide to inspect the vehicle.

  • Page 82: Periodic Service Schedule

    When the pedal is released it should return to the original position and the motor should rotate freely or go into motor braking mode. All Club Car vehicles operate at reduced speed in reverse. • General: Listen for any unusual noises such as squeaks or rattles. Check the vehicle’s ride and perfor- mance.
  • Page 83 PERIODIC MAINTENANCE Periodic Service Schedule NOTE: If the vehicle is constantly subjected to heavy use or severe operating conditions, the preventive maintenance procedure should be performed more often than recommended in the periodic service and lubrication schedules. Both the Periodic Service Schedule and the Periodic Lubrication Schedule must be followed to keep vehicle in optimum operating condition.

  • Page 84: Periodic Lubrication Schedule

    PERIODIC MAINTENANCE Periodic Lubrication Schedule PERIODIC LUBRICATION SCHEDULE See General Warnings, Section 1, Page 1-1. PERIODIC LUBRICATION SCHEDULE LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINT Semiannually by owner or trained technician Charger receptacle WD-40 (every 50 hours of operation or 100 rounds of golf) Brake system, per maintenance Dry Moly Lube (CCI P/N 1012151),...

  • Page 85: Section 11 - Electrical System And Testing

    SECTION 11 – ELECTRICAL SYSTEM AND TESTING ∆ DANGER • See General Warnings, Section 1, Page 1-1. ∆ WARNING • See General Warnings, Section 1, 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 86 Once vehicle speed slows to below approximately 11 mph (17.7 km/h), with the accelerator pedal still released, motor braking will be deac- tivated and the vehicle will coast freely. This feature is selectable. Contact your Club Car dealer/distrib- utor to inquire about this selectable feature.

  • Page 87: Electrical Circuits

    ELECTRICAL SYSTEM AND TESTING Electrical Circuits ELECTRICAL CIRCUITS See General Warnings, Section 1, Page 1-1. The IQ System vehicle has three distinct circuits: • Control circuit (Figure 11-2, Page 11-6) • Power circuit (Figure 11-4, Page 11-9) • Charge circuit (Figure 11-5, Page 11-10). CONTROL CIRCUIT The control circuit consists of three individual circuits: •...
  • Page 88 ELECTRICAL SYSTEM AND TESTING Electrical Circuits SONIC WELD NINE-PIN CONNECTOR SONIC WELD SONIC WELD BATTERY BANK SIX-PIN CONNECTOR SOLENOID CONTROLLER (PIN 5) LIGHT BLUE WIRE (PIN 6) GREEN WIRE Figure 11-1 Onboard Computer Circuit Page 11-4 2004 Precedent IQ System Golf Car Maintenance and Service Manual...
  • Page 89 ELECTRICAL SYSTEM AND TESTING Electrical Circuits The following chart describes the function of each wire of the onboard computer. OBC WIRE FUNCTION Main power supply for the onboard computer. The vehicle Red (18-gauge) batteries provide +48 volts to the onboard computer. The Tow/Run switch provides +48 volts to the OBC through the white wire when the switch is in the RUN position.
  • Page 90 ELECTRICAL SYSTEM AND TESTING Electrical Circuits Solid State Speed Control Circuit, Continued: 5. Activates the solenoid. SONIC WELD BATTERY BANK (PIN 1) WHITE/BLACK WIRE (PIN 2) YELLOW WIRE (PIN 3) PURPLE WIRE (PIN 13) BLACK/WHITE WIRE (PIN 14) LIGHT GREEN WIRE (PIN 15) RED WIRE (PIN 16) BLUE WIRE (PIN 8) WHITE WIRE...
  • Page 91 ELECTRICAL SYSTEM AND TESTING Electrical Circuits The following chart describes the function of each wire connected to the 16-pin connector at the speed con- troller. SPEED CONTROLLER 16-PIN CONNECTOR WIRE FUNCTION Pin 1 – White/Black (18-gauge) MCOR potentiometer – positive Pin 2 –...
  • Page 92 ELECTRICAL SYSTEM AND TESTING Electrical Circuits Tow/Run Switch Circuit, Continued: 7. Provides power to the Forward/Reverse switch. SONIC WELD SONIC WELD BATTERY SIX-PIN CONNECTOR (PIN 9) GRAY WIRE (PIN 10) TAN WIRE (PIN 12) BLUE/WHITE WIRE (PIN 5) LIGHT BLUE WIRE (PIN 6) GREEN WIRE (PIN 7) ORANGE/WHITE WIRE (PIN 8) WHITE WIRE...

  • Page 93: Electric Motor

    ELECTRICAL SYSTEM AND TESTING Electrical Circuits POWER CIRCUIT The function of the power circuit is to supply voltage from the battery pack to the motor. When motor braking is activated, the power circuit will direct motor-generated current to the batteries. The power circuit consists of: •...

  • Page 94: Charge Circuit

    ELECTRICAL SYSTEM AND TESTING Electrical Circuits CHARGE CIRCUIT The charge circuit consists of: • Onboard computer • Battery charger • DC charger plug • Charger receptacle • Battery pack The charge circuit supplies current from the battery charger to the batteries when the DC cord is plugged into the vehicle’s charger receptacle.

  • Page 95: Wiring Diagram

    ELECTRICAL SYSTEM AND TESTING Wiring Diagram WIRING DIAGRAM SONIC WELD SONIC WELD SPADE FUSE CONNECTOR SPADE BATTERY CONNECTOR DIODE SONIC WELD SONIC WELD SIX-PIN CONNECTOR (PIN 9) GRAY WIRE (PIN 1) WHITE/BLACK WIRE (PIN 10) TAN WIRE (PIN 2) YELLOW WIRE (PIN 3) PURPLE WIRE (PIN 12) BLUE/WHITE WIRE (PIN 5) LIGHT BLUE WIRE...

  • Page 96: Troubleshooting

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

  • Page 97: Troubleshooting Guide 2

    ELECTRICAL SYSTEM AND TESTING Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Test Menu – SPEED PULSES menu Loose or disconnected motor speed Repair and/or connect the three-pin item indicates that speed pulses are sensor or broken wire connector to the motor speed sensor OFF when the vehicle is in motion Loose or disconnected 16-pin connector Repair and/or connect the 16-pin...
  • Page 98 ELECTRICAL SYSTEM AND TESTING Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Diagnostic Menu – HW FAILSAFE Armature drive FET’s (field-effect Replace the speed controller. See Speed (Hardware Failsafe) fault code transistors) inside speed controller have Controller Removal, Section 12, failed Page 12-11.
  • Page 99 ELECTRICAL SYSTEM AND TESTING Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Diagnostic Menu – OPEN ARMATURE Loose or disconnected motor armature Repair and/or connect the motor armature fault code wires at motor or speed controller or wires broken wire Failure of the motor armature or brushes Section 15 –...
  • Page 100 ELECTRICAL SYSTEM AND TESTING Troubleshooting TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Vehicle does not operate, continued High pedal detect Cycle accelerator pedal Motor stall Cycle accelerator pedal Motor Failure See Section 15 – Motor. Replace speed controller. See Speed Speed controller failure Controller Removal, Section 12, Page 12-11.

  • Page 101: Test Procedures

    ELECTRICAL SYSTEM AND TESTING Test Procedures TEST PROCEDURES Using the following procedures, the entire IQ electrical system can be tested without major disassembly of the vehi- cle. ∆ WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured.

  • Page 102: Index Of Test Procedures

    ELECTRICAL SYSTEM AND TESTING Test Procedures INDEX OF TEST PROCEDURES 1. Batteries / Voltage Check 2. Onboard Computer Solenoid Lockout Circuit 3. Solenoid Activating Coil 4. MCOR Voltage 5. A1 and A2 Motor Voltage 6. Tow/Run Switch 7. Battery Pack Voltage (Under Load) 8.
  • Page 103 ELECTRICAL SYSTEM AND TESTING Test Procedures Batteries / Voltage Check without the IQDM Handset 1. With batteries connected and using a multimeter set to 200 volts DC, place red (+) probe on the positive (+) post of battery no. 1 and the black (–) probe on the negative (–) post of battery no. 4 (Figure 11-8, Page 11-19).
  • Page 104 ELECTRICAL SYSTEM AND TESTING Test Procedures Batteries / Voltage Check without the IQDM Handset, Continued: 6. If the dash light does not illuminate and the vehicle does not operate, check the OBC activation circuit. 6.1. Using a multimeter set to 200 volts DC, place the black (–) probe on the battery no. 4 negative post and place the red (+) probe (with insulation-piercing probe) on the red 18-gauge wire located on the OBC side of the six-pin connector.
  • Page 105 ELECTRICAL SYSTEM AND TESTING Test Procedures TEST PROCEDURE 4 – MCOR VOLTAGE See General Warnings, Section 1, Page 1-1. The accelerator position, which is proportional to the MCOR voltage, can be displayed with the IQDM hand- set. If an IQDM handset is not available, proceed to MCOR Voltage Test without the IQDM Handset on page 11-21.
  • Page 106 ELECTRICAL SYSTEM AND TESTING Test Procedures MCOR Voltage Test without the IQDM Handset, Continued: 6. With multimeter set to 20 volts DC, place the black (–) probe on battery no. 4 negative post and the red (+) probe (with insulation-piercing probe) on the no. 18 yellow wire at a point close to three-pin connector at the MCOR.
  • Page 107 ELECTRICAL SYSTEM AND TESTING Test Procedures 4.1. If there is no voltage reading, check the MCOR. See Test Procedure 4 – MCOR Voltage on page 11-21. Also check the continuity of the large posts of the solenoid. See Test Procedure 14 –...
  • Page 108 ELECTRICAL SYSTEM AND TESTING Test Procedures TEST PROCEDURE 7 – BATTERY PACK VOLTAGE (UNDER LOAD) See General Warnings, Section 1, Page 1-1. 1. Be sure the batteries are fully charged and that the electrolyte level is correct in all cells. 2.
  • Page 109 ELECTRICAL SYSTEM AND TESTING Test Procedures 4.2. While monitoring the IQDM display screen, turn the key switch to the ON position. The IQDM should indicate ON. 4.3. If the IQDM does not indicate that KEY INPUT is ON when the key switch is in the ON position, pro- ceed to the following procedure, Key Switch and MCOR Limit Switch Circuit Test without the IQDM Handset.
  • Page 110 ELECTRICAL SYSTEM AND TESTING Test Procedures Key Switch and MCOR Limit Switch Circuit Test without the IQDM Handset, Continued: ∆ WARNING • The forward/reverse switch must be in the neutral position to avoid personal injury due to contact with rotating wheels. 5.2.
  • Page 111 ELECTRICAL SYSTEM AND TESTING Test Procedures If the results of any of the referenced procedures are different from those described in the procedure, check the continuity of the wires in the wire harness and test the connected components with the appropriate test procedures.
  • Page 112 ELECTRICAL SYSTEM AND TESTING Test Procedures Test Procedure 9A – Pins 1, 2, and 3, Continued: WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 20k (ohm) SETTING (READING WITH PEDAL NOT PRESSED) SPEED CONTROLLER Figure 11-11 Pins 1, 2, and 3 Test 7.
  • Page 113 ELECTRICAL SYSTEM AND TESTING Test Procedures SPEED CONTROLLER WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV SETTING (READING WITH OBC POWERED-UP AND BATTERY CHARGER DISCONNECTED) Figure 11-12 Pin 5 Test 5. 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 114 ELECTRICAL SYSTEM AND TESTING Test Procedures Test Procedure 9C – Pin 6, Continued: SPEED CONTROLLER WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV SETTING (READING WITH OBC POWERED-UP AND ACCELERATOR PEDAL PRESSED) Figure 11-13 Pin 6 Test 4.
  • Page 115 ELECTRICAL SYSTEM AND TESTING Test Procedures • Key switch and MCOR limit switch for proper operation. See Test Procedure 8 – Key Switch and MCOR Limit Switch Circuit on page 11-24. Test Procedure 9D – Pin 7 See General Warnings, Section 1, Page 1-1. Pin 7 in the 16-pin connector provides a connection point for the reverse buzzer to the speed controller.
  • Page 116 ELECTRICAL SYSTEM AND TESTING Test Procedures Test Procedure 9E – Pins 8 and 16 See General Warnings, Section 1, 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.
  • Page 117 ELECTRICAL SYSTEM AND TESTING Test Procedures SPEED CONTROLLER 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 11-15 Pins 8 and 16 Test • Tow/Run switch for proper operation. See Test Procedure 6 – Tow/Run Switch on page 11-23. Test Procedure 9F –...
  • Page 118 ELECTRICAL SYSTEM AND TESTING Test Procedures Test Procedure 9F – Pin 9, Continued: SPEED CONTROLLER WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 200 DCV SETTING (READING WITH TOW/RUN SWITCH IN RUN POSITION) Figure 11-16 Pin 9 Test 8. With the Tow/Run switch in the RUN position, the multimeter should indicate full battery voltage (approx- imately 48 volts).
  • Page 119 ELECTRICAL SYSTEM AND TESTING Test Procedures SPEED CONTROLLER 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 11-17 Pin 10 Test 5. 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 120 ELECTRICAL SYSTEM AND TESTING Test Procedures Test Procedure 9H – Pin 12, Continued: SPEED CONTROLLER Figure 11-18 Pin 12 Test 6. Place the Tow/Run switch in the RUN position and the key switch in the ON position. 7. The solenoid should click when the key switch is placed in the ON position. 8.
  • Page 121 ELECTRICAL SYSTEM AND TESTING Test Procedures • Onboard computer gray wire. See Test Procedure 11 – Onboard Computer Gray Wire on page 11-37. • Red wire at the charger receptacle. See Test Procedure 12 – Voltage at Charger Receptacle Red Wire Socket on page 11-37.
  • Page 122 ELECTRICAL SYSTEM AND TESTING Test Procedures TEST PROCEDURE 13 – MOTOR SPEED SENSOR See General Warnings, Section 1, Page 1-1. Motor Speed Sensor Test with the IQDM Handset ∆ CAUTION • Perform the following procedure only on a level surface. To avoid injury or property damage, ensure that the path of the vehicle is clear before pushing vehicle.
  • Page 123 ELECTRICAL SYSTEM AND TESTING Test Procedures 6. Reconnect the three-pin connector at the motor speed sensor. Using a multimeter set to 20 volts DC, place the black (–) probe on the battery no. 4 negative post and place the red (+) probe (with insulation- piercing probe) on the green wire between the three-pin connector and the motor speed sensor.
  • Page 124 ELECTRICAL SYSTEM AND TESTING Test Procedures TEST PROCEDURE 15 – FORWARD/REVERSE ROCKER SWITCH See General Warnings, Section 1, Page 1-1. Forward/Reverse Rocker Switch Test with the IQDM Handset 1. Turn the key switch to the OFF position and place the Forward/Reverse switch in the NEUTRAL position. 2.
  • Page 125 ELECTRICAL SYSTEM AND TESTING Test Procedures TEST PROCEDURE 16 – REVERSE BUZZER See General Warnings, Section 1, Page 1-1. 1. Disconnect the battery cables as instructed. See WARNING "To avoid unintentionally starting..." in General Warnings, Section 1, Page 1-2. 2. Remove the instrument panel. See step 2 of Key Switch Removal, Section 12, Page 12-1. 3.

  • Page 126: Communication Display Module (Cdm)

    Last charge termination type (1 = Incomplete, 2 = DVDT, 4 = Normal, 8 = Max. timer). POWER Club Car PART #17075 Figure 11-20 CDM The CDM can be used to retrieve from the onboard computer four important items of information that can be useful in troubleshooting the IQ System vehicle.

  • Page 127: Using The Cdm To Retrieve Data From The Onboard Computer

    ELECTRICAL SYSTEM AND TESTING Communication Display Module (CDM) • F1 – Battery voltage: This displays the battery pack’s current state of charge. A reading of less than 48 volts indicates that the batteries need to be charged. If a reading of less than 48 volts is obtained immediately after a charge cycle, there may be a problem in the charge circuit.

  • Page 128: Cdm Troubleshooting Guide

    NOTE: The values of all four functions can be recalled by pressing and releasing the CDM button. CDM TROUBLESHOOTING GUIDE Use the following chart as a starting point for troubleshooting problems with communication between the CDM and onboard computer. Contact your Club Car representative for more comprehensive information. OBC Will Not Communicate With The CDM...

  • Page 129: Section 12 - Electrical Components

    SECTION 12 – ELECTRICAL COMPONENTS ∆ DANGER • See General Warnings, Section 1, Page 1-1. ∆ WARNING • See General Warnings, Section 1, Page 1-1. KEY SWITCH See General Warnings, Section 1, Page 1-1. Testing the Key Switch See Test Procedure 8, Section 11, Page 11-24. Key Switch Removal 1.
  • Page 130 ELECTRICAL COMPONENTS Key Switch Key Switch Removal, Continued: 3. Disconnect the wires from the key switch. 4. From the back of the instrument panel, push down on the retaining tabs surrounding the key switch (4) and remove the key switch cap (8). Hold the key switch and remove the switch retaining nut (6) from the outside of the instrument panel.

  • Page 131: Battery Warning Light

    ELECTRICAL COMPONENTS Battery Warning Light BATTERY WARNING LIGHT See General Warnings, Section 1, Page 1-1. Testing the Battery Warning Light See Test Procedure 18, Section 11, Page 11-42. Battery Warning Light Removal 1. Disconnect the battery cables as instructed. See WARNING "To avoid unintentionally starting..." in General Warnings, Section 1, Page 1-2.

  • Page 132: Forward/Reverse Rocker Switch

    ELECTRICAL COMPONENTS Battery Warning Light FORWARD/REVERSE ROCKER SWITCH See General Warnings, Section 1, Page 1-1. Testing the Forward/Reverse Rocker Switch See Test Procedure 15, Section 11, Page 11-40. Forward/Reverse Rocker Switch Removal 1. Disconnect the battery cables as instructed. See WARNING "To avoid unintentionally starting..." in General Warnings, Section 1, Page 1-2.

  • Page 133: Electronics Module Cover

    ELECTRICAL COMPONENTS Electronics Module Cover ∆ 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 134: Tow/Run Switch

    ELECTRICAL COMPONENTS Tow/Run Switch ELECTRONICS MODULE TOW/RUN SWITCH BRACKET Figure 12-5 Electronics Module Cover TOW/RUN SWITCH See General Warnings, Section 1, Page 1-1. Testing the Tow/Run Switch See Test Procedure 6, Section 11, Page 11-23. Tow/Run Switch Removal 1. Disconnect the battery cables as instructed. See WARNING "To avoid unintentionally starting..." in General Warnings, Section 1, Page 1-2.

  • Page 135: Motor Controller Output Regulator (Mcor)

    ELECTRICAL COMPONENTS Motor Controller Output Regulator (MCOR) BLUE PINK Figure 12-6 Tow/Run Switch MOTOR CONTROLLER OUTPUT REGULATOR (MCOR) See General Warnings, Section 1, Page 1-1. Testing the MCOR See Section 11, Test Procedure 4, Page 11-21 and Test Procedure 8, Page 11-24. MCOR Removal 1.

  • Page 136: Reverse Buzzer

    ELECTRICAL COMPONENTS Reverse Buzzer MCOR Installation 1. Secure the MCOR (2) to the pedal group with two hex-head screws (3) (Figure 12-7, Page 12-7). Tighten screws to 23 in-lb (2.6 N·m). 2. Connect the two-pin and three-pin connectors (1) from the wire harness to the MCOR. 3.

  • Page 137: Electronics Module

    ELECTRICAL COMPONENTS Electronics Module REVERSE BUZZER VIEWED FROM UNDERSIDE OF INSTRUMENT PANEL PINK ORANGE/ WHITE Figure 12-8 Reverse Buzzer ELECTRONICS MODULE See General Warnings, Section 1, 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 138 ELECTRICAL COMPONENTS Electronics Module POWER CONNECTIONS YELLOW GREEN WHITE BLACK 16-PIN CONNECTOR BLUE ORANGE MOTOR 4-PIN CONNECTOR ORANGE AND RED GRAY WIRE TO OBC TO CHARGER RECEPTACLE YELLOW FROM CONTROLLER 6-PIN SOLENOID CONNECTOR OBC FROM DRIVER SIDE BLACK WIRE TO CONTROLLER Figure 12-9 Electronics Module Removal Page 12-10 2004 Precedent IQ System Golf Car Maintenance and Service Manual...

  • Page 139: Solid State Speed Controller

    ELECTRICAL COMPONENTS Solid State Speed Controller Electronics Module Installation 1. Insert the electronics module into the vehicle. Ensure the orientation is correct, with the computer toward the front, the controller toward the rear, and both facing the passenger side of the vehicle. 2.

  • Page 140: Solenoid

    ELECTRICAL COMPONENTS Solenoid Speed Controller Installation, Continued: 4. Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first. Tighten battery terminals to 110 in-lb (12.4 N·m) and coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion.

  • Page 141: Onboard Computer (Obc)

    ELECTRICAL COMPONENTS Onboard Computer (OBC) 3. Remove 4 wires from solenoid. 4. Loosen both solenoid mounting screws (2) (Figure 12-10, Page 12-12). 5. Rotate solenoid up in front and slide off of the component mounting plate. Solenoid Installation 1. Mount solenoid onto component mounting plate with screws (2) (Figure 12-10, Page 12-12). 2.

  • Page 142: Charger Receptacle

    ELECTRICAL COMPONENTS Charger Receptacle CHARGER RECEPTACLE See General Warnings, Section 1, 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 143 ELECTRICAL COMPONENTS Charger Receptacle GREY BLACK TO OBC TO CONNECTOR TO BATTERY 1 (+) POST TYPICAL 3 PLACES Figure 12-11 Charger Receptacle 2004 Precedent IQ System Golf Car Maintenance and Service Manual Page 12-15...

  • Page 145: Section 13 - Batteries

    The outward appearance of these two batteries is similar, but the operating characteristics are very different. The Club Car electric vehicle battery is a deep-cycle battery, and the automotive battery is a “starting, lighting and ignition” (SLI) battery. They should never be substituted for one another.
  • Page 146 BATTERIES General Information During discharge, the chemical reaction inside the battery causes the sulfate (SO ) to break away from the H (Figure 13-2, Page 13-2). The sulfate (SO ) combines with the lead (Pb) on both plates, forming lead sulfate (PbSO ).

  • Page 147: Common Misconceptions About Batteries

    BATTERIES Battery Replacement COMMON MISCONCEPTIONS ABOUT BATTERIES The chart below describes some of the more common misconceptions that are associated with deep-cycle vehicle batteries and battery care. PROBLEM MISCONCEPTION REALITY Avoid deep discharge of batteries whenever “This vehicle is running slowly, but we can run Deep-discharge possible.

  • Page 148: Battery Care

    BATTERIES Battery Care Battery Replacement, Continued: 3. If the battery cables are to be reused, inspect them for broken or frayed wires, damaged terminals, or worn insulation. Remove any corrosion on the connectors. A solution of baking soda and water (1 cup (237 mL) baking soda per 1 gallon (3.8 L) of water) does an excellent job of neutralizing and removing the corrosion.

  • Page 149: Self-Discharge

    BATTERIES Battery Care 2. Batteries should be clean and free of corrosion. Wash tops and terminals of batteries with a solution of baking soda and water (1 cup (237 mL) baking soda per 1 gallon (3.8 L) of water). Rinse solution off bat- teries.

  • Page 150: Mineral Content

    BATTERY CHARGING See General Warnings, Section 1, Page 1-1. The charger supplied with the Club Car electric vehicle resolves the most common problems associated with battery charging. Undercharging and overcharging are prevented provided the charger is allowed to shut off by itself.

  • Page 151: Charger Shuts Off After 16 Hours

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

  • Page 152: Battery Troubleshooting Chart

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

  • Page 153: Battery Testing

    BATTERIES Battery Testing BATTERY TESTING See General Warnings, Section 1, 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 13-7, Page 13-8).
  • Page 154 BATTERIES Battery Testing Performing the Hydrometer Test, Continued: 5. Hold the hydrometer vertically, ensuring that the float is not touching the sides of the barrel. Hold the hydrometer at eye level and read the scale at the level of electrolyte (Figure 13-8, Page 13-10). 6.

  • Page 155: Discharge Test

    BATTERIES Battery Testing CORRECTED SPECIFIC GRAVITY VEHICLE BATTERY ELECTROLYTE CORRECTION REQUIRED TEMPERATURE FACTOR ACTION CELL 1 CELL 2 CELL 3 CELL 4 CELL 5 CELL 6 1.275 – 1.280 – 1.280 – 1.275 – 1.280 – 1.280 – 20 °F Sound Battery –...
  • Page 156 BATTERIES Battery Testing Performing the Discharge Test, Continued: 3. Check and record the electrolyte temperature of the battery packs. Check cell no. 2 (second cell from positive post) in each battery. 4. Reset discharge machine and turn the tester ON. 5.

  • Page 157: Battery Troubleshooting Examples

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

  • Page 158: Battery Storage

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

  • Page 159: Section 14 - Battery Charger

    SECTION 14 – BATTERY CHARGER Refer to the appropriate battery charger maintenance and service manual. 2004 Precedent Electric Golf Car Maintenance and Service Manual Page 14-1...

  • Page 161: Section 15 - Motor

    The IQ System vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. The shunt- wound motor is designed for use on the IQ System vehicle 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 162 MOTOR External Motor Testing External Motor Testing, Continued: Figure 15-1 Motor Short Circuit Test TEST PROCEDURE 2 – ARMATURE CIRCUIT OPEN See General Warnings, Section 1, Page 1-1. 1. Disconnect the battery cables as instructed. See WARNING "To avoid unintentionally starting..." in General Warnings, Section 1, Page 1-1.

  • Page 163: Motor

    MOTOR External Motor Testing MOTOR See General Warnings, Section 1, Page 1-1. Motor Removal 1. Disconnect the battery cables as instructed. See WARNING "To avoid unintentionally starting..." in General Warnings, Section 1, Page 1-1. 2. Using two wrenches to prevent posts from turning, disconnect wires from terminals on motor. Label the wires to ensure proper reconnection.
  • Page 164 MOTOR External Motor Testing Motor Removal, Continued: 8. To gain easier access to the motor, lower the transaxle as low as it will go. If more room is needed, remove the jack from beneath the transaxle and allow the springs to rest on the floor (Figure 15-4, Page 15-4).

  • Page 165: Motor Component Testing And Inspection

    MOTOR Motor Component Testing and Inspection MATCH MARKS ARMATURE Figure 15-5 Motor Disassembly Figure 15-6 Brush Spring Removal MOTOR COMPONENT TESTING AND INSPECTION See General Warnings, Section 1, Page 1-1. ARMATURE Visual Inspection Disassemble the motor and carefully inspect the armature for the following characteristics: •...

  • Page 166: Field Windings Inspection

    MOTOR Motor Component Testing and Inspection Visual Inspection, Continued: 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 167: Motor Components

    MOTOR Motor Component Testing and Inspection MOTOR COMPONENTS 1. Inspect the insulators (4 and 7) for cracks or other damage (Figure 15-10, Page 15-8). 2. Inspect the brushes (13) for damage or excessive wear. Replace brushes if required. See following NOTE.
  • Page 168 MOTOR Motor Component Testing and Inspection TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 3 PLACES Figure 15-10 Motor Page 15-8 2004 Precedent IQ System Golf Car Maintenance and Service Manual...

  • Page 169: Bearing Removal

    MOTOR Reconditioning the Motor BEARING REMOVAL 1. Place the wedge attachment tool (CCI P/N 1012812) between the bearing (15) and the armature (17) (Figure 15-10, Page 15-8). Make sure the wedge attachment tool is supporting the inner race of the bearing.

  • Page 170: Motor Assembly

    MOTOR Motor Assembly Motor Specifications Any rework must be performed by a qualified technician. Motor service specifications are listed in the follow- ing table. ITEM SERVICE LIMIT Commutator diameter (minimum) 2.265 in. (66.675 mm) Commutator concentric with 0.001 in. (0.0254 mm) armature shaft within Limit depth of cut when 0.005 in.
  • Page 171 MOTOR Motor Assembly PRESS WEDGE ATTACHMENT TOOL (CCI P/N 1012812) BEARING PULLER (CCI P/N 1012811) Figure 15-11 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 172: Motor Installation

    MOTOR Motor Installation Motor Assembly, Continued: END SHIELD MOUNTING SCREW RIGGING BEARING RETAINER TERMINAL POST MOUNTING Figure 15-12 Brush Installation Figure 15-13 End Shield Installation MOTOR INSTALLATION See General Warnings, Section 1, Page 1-1. 1. Clean the transaxle input shaft. ®...
  • Page 173 MOTOR Motor Installation GREASE inch inch 1/8 INCH 3/8 INCH (9.5 MM) (3.1 MM) Figure 15-14 Grease on Putty Knife Figure 15-15 Application of grease to Input Shaft Grooves 2.6. Check the chamfer and end of the input shaft to ensure these areas are completely clean of grease as shown (Figure 15-16, Page 15-13).
  • Page 174 MOTOR Motor Installation Motor Installation, Continued: 4.2. Loosely install four motor bolts and washers that secure the motor to the transaxle. Do not tighten. 4.3. Begin finger tightening the bolts (1 and 2) in the sequence indicated (Figure 15-19, Page 15-15). Continue tightening by hand until the motor is seated in the transaxle housing.

  • Page 175: Motor Speed Sensor

    MOTOR Motor Speed Sensor VIEWED FROM DRIVER SIDE Figure 15-18 Motor Installation Figure 15-19 Motor Mount MOTOR SPEED SENSOR See General Warnings, Section 1, Page 1-1. Testing the Motor Speed Sensor See Test Procedure 13, Section 11, Page 11-38. Motor Speed Sensor Removal 1.
  • Page 176 MOTOR Motor Speed Sensor Motor Speed Sensor Installation, Continued: Figure 15-20 IQ Motor Speed Sensor Page 15-16 2004 Precedent IQ System Golf Car Maintenance and Service Manual...

  • Page 177: Section 16A - Transaxle (Type G)

    • See General Warnings, Section 1, Page 1-1. TRANSAXLE IDENTIFICATION Club Car electric vehicles utilize one of two types of transaxles. The different transaxles are identified by the orientation of the gear case bolt heads: • The Type G transaxle has gear case bolt heads oriented toward the passenger side of the vehicle.
  • Page 178 TRANSAXLE (TYPE G) Axle Bearing and Shaft Axle Shaft and Oil Seal Removal, Continued: 3. Remove the rear wheel and brake drum. See Section 6 – Wheel Brake Assemblies. and Section 8 – Wheels and Tires in the appropriate maintenance and service manual. 4.
  • Page 179 TRANSAXLE (TYPE G) Axle Bearing and Shaft REFERENCE MOTOR – SECTION 15 Figure 16a-5 Transaxle – Type G 2004 Precedent IQ System Golf Car Maintenance and Service Manual Page 16a-3...
  • Page 180 TRANSAXLE (TYPE G) Axle Bearing and Shaft Axle Shaft and Oil Seal Removal, Continued: 8. Inspect bearing (5) (Figure 16a-5, Page 16a-3). If the bearing in a Type G transaxle is worn or damaged, the entire axle shaft assembly (1 or 2) must be replaced. Axle Shaft and Oil Seal Installation 1.

  • Page 181: Axle Bearing

    TRANSAXLE (TYPE G) Transaxle AXLE BEARING Do not remove the axle bearing (5) from a Type G transaxle. If bearing is worn or damaged, the entire axle assembly (1 or 2) must be replaced (Figure 16a-5, Page 16a-3). TRANSAXLE See General Warnings, Section 1, Page 1-1. TRANSAXLE REMOVAL 1.
  • Page 182 TRANSAXLE (TYPE G) Transaxle Transaxle Removal, Continued: Remove bolt, then rotate shackle up and away from spring. Figure 16a-8 Disconnect Shocks Figure 16a-9 Shackles 9. If a chain hoist was used to raise the vehicle, lift the vehicle high enough to permit easy access and clear- ance for removal of the motor.

  • Page 183: Transaxle Disassembly, Inspection, And Assembly

    TRANSAXLE (TYPE G) Transaxle Disassembly, Inspection, and Assembly 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. See preceding WARNING. 12.
  • Page 184 TRANSAXLE (TYPE G) Transaxle Disassembly, Inspection, and Assembly Transaxle Disassembly and Inspection, Continued: CAUTION • Do not damage gears. Use extreme care when handling them. 5. Use a bearing puller or arbor press to remove bearings (16) from the input pinion gear. If the oil seal (10) is damaged, replace it (Figure 16a-5, Page 16a-3).
  • Page 185 TRANSAXLE (TYPE G) Transaxle Disassembly, Inspection, and Assembly Figure 16a-14 Separate Housing 8.4. Remove the differential pin (31) by pushing pin through differential gear case from one side (Figure 16a-5, Page 16a-3). See also Figure 16a-15, Page 16a-9. 8.5. Remove the idler gears and thrust plates (1 and 2) (Figure 16a-16, Page 16a-9). 8.6.

  • Page 186: Transaxle Assembly

    TRANSAXLE (TYPE G) Transaxle Disassembly, Inspection, and Assembly TRANSAXLE ASSEMBLY CAUTION • Do not press against the bearing outer race. • The housing and all parts must be wiped clean and dry before reassembly. 1. If bearings (13) were removed during disassembly, install new bearings using an arbor press (Figure 16a-5, Page 16a-3).

  • Page 187: Transaxle Installation

    TRANSAXLE (TYPE G) Transaxle Installation in the inside wall of the axle tube hub (Figure 16a-5, Page 16a-3). 11.3. Place a 1/4 to 3/8 - inch (6 - 10 mm) diameter rod against the retaining ring and tap lightly at four or five locations to ensure it is properly seated.
  • Page 188 TRANSAXLE (TYPE G) Transaxle Installation ∆ 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 189: Section 16B - Transaxle (Type K)

    • See General Warnings, Section 1, Page 1-1. TRANSAXLE IDENTIFICATION Club Car electric vehicles utilize one of two types of transaxles. The different transaxles are identified by the orientation of the gear case bolt heads: • The Type G transaxle has gear case bolt heads oriented toward the passenger side of the vehicle.
  • Page 190 TRANSAXLE (TYPE K) Axle Bearing and Shaft Axle Shaft and Oil Seal Removal, Continued: 3. Remove the rear wheel and brake drum. See Section 6 – Wheel Brake Assemblies and Section 8 – Wheels and Tires in the appropriate maintenance and service manual. 4.
  • Page 191 TRANSAXLE (TYPE K) Axle Bearing and Shaft REFERENCE MOTOR — SECTION 15 Figure 16b-4 Transaxle – Type K 2004 Precedent IQ System Golf Car Maintenance and Service Manual Page 16b-3...

  • Page 192: Axle Bearing

    TRANSAXLE (TYPE K) Axle Bearing and Shaft AXLE BEARING Axle Bearing Removal 1. Remove the retaining ring (7) from the axle shaft (Figure 16b-4, Page 16b-3). 2. Place a bearing puller wedge attachment (CCI P/N 1012812) on the axle shaft between the wheel mount- ing flange and the bearing.
  • Page 193 TRANSAXLE (TYPE K) Axle Bearing and Shaft CAUTION • If the bearing was removed from the shaft, replace bearing with a new one. 4. Place the bearing puller wedge attachment against the collar and press on both the bearing and collar. See following CAUTION.

  • Page 194: Transaxle

    TRANSAXLE (TYPE K) Axle Bearing and Shaft TRANSAXLE See General Warnings, Section 1, Page 1-1. TRANSAXLE REMOVAL 1. Disconnect the battery cables as instructed. See WARNING "To avoid unintentionally starting..." in General Warnings, Section 1, Page 1-2. 2. Place chocks at the front wheels and slightly loosen lug nuts on both rear wheels. 3.
  • Page 195 TRANSAXLE (TYPE K) Axle Bearing and Shaft Remove bolt, then rotate shackle up and away from spring. Figure 16b-9 Disconnect Shocks Figure 16b-10 Shackles ∆ WARNING • Do not position fingers under motor when sliding motor off of the input shaft. Fingers may get pinched when motor disengages.

  • Page 196: Transaxle Disassembly, Inspection, And Assembly

    TRANSAXLE (TYPE K) Transaxle Disassembly, Inspection, and Assembly Transaxle Removal, Continued: Figure 16b-13 Motor Positioning Bolt TRANSAXLE DISASSEMBLY, INSPECTION, AND ASSEMBLY See General Warnings, Section 1, Page 1-1. TRANSAXLE DISASSEMBLY AND INSPECTION 1. To detach axle tubes (16 and 40) from the transaxle housing, remove the bolts and lock washers (8 and 9) (Figure 16b-4, Page 16b-3).
  • Page 197 TRANSAXLE (TYPE K) Transaxle Disassembly, Inspection, and Assembly 6. To disassemble the intermediate gear assembly, press off together the bearing (18) and the gear (23) (Figure 16b-4, Page 16b-3). See also Figure 16b-14, Page 16b-9. 7. Remove key (22) (Figure 16b-4, Page 16b-3). See also Figure 16b-15, Page 16b-9. Remove key.

  • Page 198: Transaxle Assembly

    TRANSAXLE (TYPE K) Transaxle Disassembly, Inspection, and Assembly Transaxle Disassembly and Inspection, Continued: 9.5. Remove the differential pin (31) by pushing pin through differential gear case from one side (Figure 16b-4, Page 16b-3). See also Figure 16b-18, Page 16b-10. 9.6. Remove the idler gears and thrust plates (1 and 2) (Figure 16b-19, Page 16b-10). 9.7.
  • Page 199 TRANSAXLE (TYPE K) Transaxle Disassembly, Inspection, and Assembly 2.3. Install eight hex bolts (28) and the bolt lock plates (29). Tighten the bolts to 18 ft-lb (24 N·m). 2.4. Bend the edges of the bolt locking tabs securely against the flats of the bolt heads to prevent the bolts from loosening and possibly causing damage (Figure 16b-16, Page 16b-9).

  • Page 200: Shimming The Transaxle

    TRANSAXLE (TYPE K) Transaxle Disassembly, Inspection, and Assembly Transaxle Assembly, Continued: 11.3. Place a 1/4 to 3/8 - inch (6 - 10 mm) diameter rod against the retaining ring and tap lightly at four or five locations to ensure it is properly seated. See following WARNING. ∆...

  • Page 201: Transaxle Installation

    TRANSAXLE (TYPE K) Transaxle Installation SHIMS SEAL SURFACE MEASUREMENT REQUIRED Up to .134 in. (3.4 mm) .134 -.142 in. (3.4-3.6 mm) .142 -.150 in. (3.6-3.8 mm) .150 -.155 in. (3.8-3.9 mm) TRANSAXLE INSTALLATION See General Warnings, Section 1, Page 1-1. 1.
  • Page 203 INDEX bearing, axle see transaxle, type g, axle bearing accelerator return spring ........5-4 see transaxle, type k, axle bearing access panel ............4-11 bearing, motor armature, motor see motor, bearing see motor, armature body, front ............. 4-3, 4-8 see also repair, front and rear body installation ..........
  • Page 204 INDEX retrieving data from ........11-43 front bumper and clamshell ........4-5 fuse, sense lead ..........11-37 troubleshooting ..........11-44 connector, 16-pin see test procedures high pedal detect ..........11-2 DANGER inspection definition of ............1-1 front wheel free play ........7-17 dash assembly ............ 4-14 motor installation ............
  • Page 205 INDEX bearing removal ............. 5-1 inspection ........... 15-7 Pedal Group Access ..........5-1 periodic lubrication schedule ......10-4 installation ..........15-9 periodic service schedule ......... 10-2 removal ............15-9 braking pedal down motor braking ......11-1 rack and pinion ............ 7-4 pedal up motor braking .......
  • Page 206 INDEX testing ............11-39 suspension, rear solenoid activating coil leaf spring testing ............11-20 installation .............9-4 speed controller removal ............9-1 connector, 16-pin shock absorber see test procedures inspection and removal ......... 9-1 installation .............9-1 installation ............12-11 removal ............12-11 speed sensor see motor, speed sensor test procedures...
  • Page 207 INDEX disassembly ..........16a-7 identification ..........16a-1 zero speed detect ..........11-1 inspection ............16a-7 installation ........... 16a-11 lubrication ............16a-1 oil seal installation ..........16a-4 removal ............. 16a-1 removal ............16a-5 transaxle, type k assembly ............. 16b-10 axle bearing ..........16b-4 installation ..........
  • Page 212 Club Car, Inc. www.clubcar.com Phone 1.706.863.3000 P.O. Box 204658 Augusta, GA 30917-4658 1.800.ClubCar Int’I +1 706.863.3000 1.706.863.5808...

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