Club Car 2005 Precedent Maintenance And Service
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Club Car 2005 Precedent Maintenance And Service

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Maintenance
2005
And
Service
IQ System
Electric Vehicles
Manual No. 102680401
Edition Code 0205C0306B

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Summary of Contents for Club Car 2005 Precedent

  • Page 1 Maintenance 2005 Service IQ System Electric Vehicles Manual No. 102680401 Edition Code 0205C0306B...
  • 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 its vehicles and other products. These improvements may affect servicing procedures.

  • Page 5: Table Of Contents

    Front Bumper ............................ Instrument Panel ..........................Instrument Panel Removal ......................Instrument Panel Installation ......................Floor Mat and Retainers ........................Floor Mat Retainer Removal ......................Floor Mat Retainer Installation ...................... 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page iii...
  • Page 6 Brake Shoe Installation ........................Brake Cable Equalizer Adjustment ....................Brake Cluster Removal and Installation ................... Brake Cluster Installation ......................6-10 Brake Cable Removal and Installation ..................... 6-11 Page iv 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 7 7-17 Front Hub Removal ........................7-17 Hub Installation ..........................7-17 SECTION 8 – WHEELS AND TIRES General Information .......................... Wheels .............................. Wheel Removal ..........................Wheel Installation ......................... 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page v...
  • Page 8 Index of Test Procedures ......................11-14 Communication Display Module (CDM) ................... 11-38 Using the CDM to Retrieve Data from the Onboard Computer ............ 11-39 CDM Troubleshooting Guide ......................11-40 Page vi 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 9 Battery Charger Test ........................13-7 On-Charge Voltage Test ....................... 13-7 Hydrometer Test ........................... 13-7 Discharge Test ..........................13-9 Battery Troubleshooting Examples ....................13-11 Battery Storage ..........................13-12 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page vii...
  • Page 10 15b-6 Motor Frame and Field Windings Inspection ................15b-8 Motor Brush, Spring, and Terminal Insulator Inspection .............. 15b-8 Reconditioning the Motor ......................... 15b-11 Motor Assembly ..........................15b-11 Page viii 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 11 Transaxle Removal ........................16-5 Transaxle Disassembly, Inspection, and Assembly ................16-7 Transaxle Disassembly and Inspection ..................16-7 Transaxle Assembly ........................16-9 Transaxle Installation ........................16-10 SECTION i – INDEX 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page ix...

  • Page 13: 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 CAU- TION.
  • Page 14 Place Tow/Run cable first. switch in TOW. FRONT OF VEHICLE Place TOW/RUN Switch in the TOW position before disconnecting or connecting battery cables. Figure 1-1 Battery Disconnection Page 1-2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 15: Section 2 - Vehicle Specifications

    4.5 in. 4.5 in. Ground clearance (11 cm) (11 cm) 34.5 in. 34.5 in. Front wheel tread (88 cm) (88 cm) Vehicle Specifications continued on next page... 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 2-1...

  • Page 16: Specifications

    Two- Four- Passenger Passenger SPECIFICATIONS Electric Electric Vehicle Vehicle 38.6 in. 38.6 in. Rear wheel tread (98 cm) (98 cm) 855 lb. 970 lb. Weight (standard electric vehicle with canopy, with batteries) (388 kg) (440 kg) Weight (standard gasoline vehicle with canopy, with battery, without fuel) Forward speed 12-15 mph (19-24 km/h) 17 ft - 4in.

  • Page 17: 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 18: Safety Committee

    • 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. • Place Tow/Run switch in the TOW position. Page 3-2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 19: Preparing The Electric Vehicle For Extended Off-Season Storage

    Frozen batteries can explode. 3. Adjust tire to recommended pressure. See Section 2 – Vehicle Specifications. 4. Perform the Pre-Operation and Daily Safety Checklist. See Section 10 – Periodic Maintenance. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 3-3...

  • Page 21: 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 22: Front And Rear Body Repair

    GOUGES, PUNCTURES, TEARS, LARGE SCRATCHES, AND ABRASIONS Touch-up is not recommended. Replace the entire body part or have it repaired by a professional paint and body repair shop with experience repairing Surlyn bodies. Page 4-2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 23 BODY AND TRIM Front and Rear Body Repair TYPICAL 4 PLACES TYPICAL 5 PLACES TYPICAL 5 PLACES Figure 4-1 Front Body 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 4-3...

  • Page 24: Front Body

    3. Disconnect the electrical connector on the passenger side of the instrument panel (3) and remove the panel. 4. Remove two barrel fasteners (7) to release dash tray (6). 5. Remove three screws (2) and remove dash assembly (1) from vehicle. Page 4-4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 25 BODY AND TRIM Instrument Panel UNDERBODY FRONT SUSPENSION Figure 4-2 Bracket and Front Bumper TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES Figure 4-3 Instrument Panel 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 4-5...

  • Page 26: Instrument Panel Installation

    (1) (Figure 4-4, Page 4-6). TO BODY TRIM CLIPS 4 PLACES Figure 4-4 Floor Mat Retainer Page 4-6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 27: Floor Mat Retainer Removal

    2. Install two front screws (3) to secure the rear beauty panel. Tighten screws to 3.7 ft-lb (5 N·m). 3. Install floor mat. See Floor Mat and Retainers, Section 4, Page 4-6. 4. Snap charger bezel (4) in place on the kick plate. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 4-7...

  • Page 28: Rear Body - Two-Passenger Vehicles

    Accessories that can be mounted to the SAM include single or dual sand bottles, sand bucket, and the club cleaner. ATTACHMENT POINTS Figure 4-6 Universal Accessory Mounting Page 4-8 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 29 BODY AND TRIM Rear Body – Two-Passenger Vehicles TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES Figure 4-7 Backrest and SAM 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 4-9...

  • Page 30: Backrest And Structural Accessory Module (Sam)

    4. Remove two screws (14) and remove Forward/Reverse switch housing (15) from vehicle. 5. Disconnect electrical wires from the Forward/Reverse switch (16). 6. Lift rear beauty panel from vehicle. Page 4-10 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 31 BODY AND TRIM Rear Body – Two-Passenger Vehicles TWO-PASSENGER VEHICLES ONLY TYPICAL 4 PLACES WHITE BLUE BODY CLIPS TWO-PASSENGER VEHICLES ONLY TWO-PASSENGER VEHICLES ONLY Figure 4-8 Rear Body Components 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 4-11...

  • Page 32: Rear Body - Four-Passenger Vehicles

    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 4-11, Page 4-15). Page 4-12 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 33: Seat Support

    124 in-lb (14 N·m) (Figure 4-9, Page 4-13). TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES Figure 4-9 Seat Supports (Four-Passenger Vehicles) 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 4-13...

  • Page 34: Foot Deck

    4. Remove the four bolts (2) securing the foot deck (1) to the vehicle frame (Figure 4-10, Page 4-14). Foot Deck Installation 1. Install foot rest in reverse order of removal. 2. Tighten bolts (2) to 71 in-lb (8 N·m) (Figure 4-10, Page 4-14) Page 4-14 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

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

    3. Remove two screws (14) and remove the Forward/Reverse switch housing (15) from vehicle. 4. Disconnect electrical wires from the Forward/Reverse switch (16). 5. Lift rear beauty panel from vehicle. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 4-15...

  • Page 36: Canopy - Two-Passenger

    6. Remove two bolts (11) from each front canopy support (7 and 10) and remove canopy supports from the vehicle. 7. Remove two bolts (6) from each rear support (3) and pull rear supports from vehicle. Page 4-16 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 37 BODY AND TRIM Canopy – Two-Passenger Figure 4-12 Precedent Two-Passenger Canopy 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 4-17...

  • Page 38: Two-Passenger Canopy Installation

    9. Position each cover (12 and 13) over its respective support. A hole in each cover should be aligned with a corresponding hole in the support. Secure the cover to the support with a screw (14). Tighten the screws (14) to 31 in-lb (4.6 N·m). Page 4-18 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 39 2 PLACES 2 PLACES REF. TYPICAL 4 PLACES TYPICAL 2 PLACES REF. SEATS REMOVED FOR CLARITY TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 4-13 Precedent Four-Passenger Canopy 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 4-19...

  • Page 40: Canopy - Four-Passenger

    6. Tighten the four bolts (2) installed in step 1.2 to 18 ft-lb (25 N·m). 7. Secure each front support cover (4) with one screw (5). Tighten the hardware to 53 in-lb (6 N·m). Page 4-20 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 41: Section 5 - Accelerator And Brake Pedal Group

    4. Lift off cover plate (7) (Figure 5-2, Page 5-2). 5. Loosen jam nuts (4 and 5) on each side of turnbuckle (6). 6. Nut (4) has a left-hand thread. Figure 5-1 Pedal Group Access 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 5-1...
  • Page 42 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group TYPICAL 2 PLACES TYPICAL 2 PLACES ELECTRICAL CONNECTIONS Figure 5-2 Pedal Group Page 5-2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 43: Mcor

    The brake return spring (5) provides the pressure needed to return the brake pedal to its upright position (Figure 5-4, Page 5-5). One end of the spring attaches to a hook on pedal (11) and the other end attaches to pedal base (12). 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 5-3...

  • Page 44: Pawl Assembly

    4. Push accelerator pedal forward to compress the springs in the assembly. While the springs are com- pressed, pull pin from both T-shaped bars then release the pedal (Figure 5-7, Page 5-6). Page 5-4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 45 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group OPPOSITE SIDE VIEW Typical 3 places Figure 5-4 Brake Pedal 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 5-5...

  • Page 46: Pedal Group Installation

    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). Page 5-6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 47: Section 6 - Wheel Brake Assemblies

    NOTE: When servicing vehicles with severely worn brake shoes and when the drums cannot be removed by normal methods, proceed to step 7 to minimize damage to the brake cluster and brake compo- nents. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 6-1...
  • Page 48 8.1. Using 90° snap ring pliers (CCI P/N 1012560), remove the axle retaining ring (1) (Figure 6-3, Page 6-2). 8.2. Pull the axle shaft (2) from the axle tube (Figure 6-3, Page 6-2). Figure 6-3 Remove Axle Retaining Ring Page 6-2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 49 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 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 6-3...
  • Page 50 11. Remove adjuster wheel (1) with two washers (2 and 3) from the backing plate (Figure 6-7, Page 6-4). Figure 6-7 Remove Adjuster Wheel Figure 6-8 Lubricate Slide and Slide Plate Page 6-4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 51: Brake Assembly Cleaning

    (Figure 6-11, Page 6-6). See preceding WARNING. 7. Install the adjuster wheel (1) and two washers (2 and 3) into the adjuster assembly (Figure 6-7, Page 6-4). 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 6-5...

  • Page 52: Brake Shoe Installation

    SILVER SPRING spring is mounted with the coils to the side of the adjustment lever spring (A). Figure 6-13 Install Trailing Shoe Retainer Clip Figure 6-14 Attach Springs Page 6-6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 53 Continue advancing the shaft until the bearing on the axle is firmly seated within the axle tube hub seat. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 6-7...
  • Page 54 Installation, Section 8, Page 8-1. 10. Adjust brake cable equalizer. See Brake Cable Equalizer Adjustment on page 6-9. JAM NUT (1 OF 2) EQUALIZER TURNBUCKLE Figure 6-18 Equalizer Adjustment Page 6-8 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 55: Brake Cable Equalizer Adjustment

    7.2. Pull the axle shaft (2) from the axle tube (Figure 6-3, Page 6-2). 8. Remove bow tie locking pin (13) and clevis pin (12) from brake cable (Figure 6-4, Page 6-3). 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 6-9...

  • Page 56: Brake Cluster Installation

    5. Tighten lug nuts on rear wheels, using a crisscross pattern, to 55 ft-lb (74.6 N·m). See Wheel Installa- tion, Section 8, Page 8-1. 6. Adjust the brakes. See Brake Cable Equalizer Adjustment on page 6-9. Page 6-10 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 57: Brake Cable Removal And Installation

    11. Using brake cable release tool (CCI P/N 102555501), compress the retaining clips on the end of the cable housing enough to slip the cable end out of the bracket (4) and remove the brake cable from the vehicle. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 6-11...

  • Page 58: Brake Cable Installation

    5. Place tab (3) on cable housing over the forward leaf spring mounting bolt (2) (Figure 6-21, Page 6-12). Install nut (1). Tighten nut to 18.4 ft-lb (25 N·m). 6. Adjust the brakes. See Brake Cable Equalizer Adjustment on page 6-9. Page 6-12 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 59: Section 7 - Steering And Front Suspension

    6.4. Using a 1/2 inch drive air impact wrench, tighten the anvil screw (6) until the steering wheel breaks free from the steering shaft. 6.5. Remove the steering wheel puller. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 7-1...

  • Page 60: Steering Wheel Installation

    2. Remove the steering wheel as previously instructed. 3. Remove the dash insert, instrument panel, dash assembly, and front bumper. See Section 4 – Body and Trim. Page 7-2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 61 Steering Column APPEARANCE OF SCORECARD HOLDER MAY BE DIFFERENT THAN THAT SHOWN TYPICAL 2 PLACES NOT REQUIRED FOR SOME SCORECARD HOLDERS TYPICAL 4 PLACES Figure 7-3 Steering Column 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 7-3...

  • Page 62: Steering Column Installation

    4. Remove the three bolts (5) from the steering rack and pinion assembly mounting bracket. 5. Remove the bolt (6) from the universal joint, then remove the rack and pinion assembly and universal joint from the vehicle. Page 7-4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 63: Rack And Pinion Disassembly

    (Figure 7-8, Page 7-7). Gently pry the pinion from the housing. 9. Remove the universal joint from the pinion (5). 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 7-5...
  • Page 64 STEERING AND FRONT SUSPENSION Rack and Pinion Figure 7-5 Steering Gear Page 7-6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 65 Figure 7-6 Remove Dust Seal Figure 7-7 Pinion Snap Rings PRESS RAM PINION GEAR BEARING Figure 7-8 Remove Pinion from Housing Figure 7-9 Remove Bearing from Pinion 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 7-7...

  • Page 66: Rack And Pinion Assembly

    16. Install the tie rod ends (12) to each end of rack (18). Tighten the tie rod end jam nuts (11) to 20 ft-lb (27 N·m) (Figure 7-5, Page 7-6). Page 7-8 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 67: Rack And Pinion Installation

    IN PLACE Figure 7-10 Press In Dust Seal Figure 7-11 Install Ball Joint DEEP WELL SOCKET Figure 7-12 Rack and Pinion Adjustment Figure 7-13 Rack and Pinion Resistance 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 7-9...

  • Page 68: Front Suspension

    See also Figure 7-14, Page 7-11. 6. Tighten the hex nut (8) on the adjustment eccentric (7) to 10 ft-lb (13.5 N·m) (Figure 7-15, Page 7-11). See also Figure 7-19, Page 7-16. Page 7-10 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 69 4. Measure the distance between the marks on the forward-facing surfaces of the tires (Figure 7-16, Page 7-11). NOTE: The front measurement must be less than the rear measurement. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 7-11...

  • Page 70: Front Suspension Components

    2. Install tie rod ends (12) into the spindle tabs. Install the retaining nuts (14) and retaining pins (15) (Figure 7-18, Page 7-15). 3. Adjust wheel toe-in. See Toe-in Adjustment on page 7-11. Page 7-12 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 71: Leaf Spring Removal

    4. Install the steering spindle on the kingpin. Place upper clevis over the kingpin threads and install conical washer (2) and nut (1). Tighten the nut to 50 ft-lb (68 N·m). 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 7-13...

  • Page 72: Control Arm Removal

    NOTE: When installing shock absorbers, make sure front shocks have identical part numbers. 1. Install the shock absorber by reversing the removal procedure. 2. Tighten the bolts to 20 ft-lb (27 N·m). Page 7-14 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 73 STEERING AND FRONT SUSPENSION Front Suspension Components Figure 7-18 Upper Front Suspension Assembly 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 7-15...
  • Page 74 STEERING AND FRONT SUSPENSION Front Suspension Components CLEVIS Figure 7-19 Lower Front Suspension Assembly Page 7-16 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 75: Front Wheel Bearings And Hubs

    7. Install wheels and finger-tighten lug nuts. 8. Lower the vehicle and finish tightening lug nuts, using a crisscross pattern, to 55 ft-lb (74.6 N·m). Figure 7-20 Front Wheel Hub 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 7-17...

  • Page 77: Section 8 - Wheels And Tires

    1. Install wheel(s) and tighten the lug nuts, using a crisscross pattern, until they are snug. 2. Lower the vehicle and finish tightening lug nuts, using a crisscross pattern, to 55 ft-lb (74.6 N·m). 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 8-1...

  • Page 78: Tires

    1.2. Immerse the tire in water and then mark the point where bubbles are formed by escaping air. 1.3. Determine the cause of the air leak. See following NOTE. Page 8-2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 79: Tire Installation

    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. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 8-3...
  • Page 80 WHEELS AND TIRES Tires Figure 8-2 Inflate Tire Page 8-4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 81: Section 9 - Rear Suspension

    Position jack stands under the frame crossmember forward of the spring mounting tabs. Lower the vehi- cle to let the jack stands support the vehicle (Figure 9-2, Page 9-3). See following WARNING. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 9-1...
  • Page 82 REAR SUSPENSION Leaf Springs (Two-Passenger Vehicles) BRAKE CABLE HANGER MOUNTING TYPICAL ON EACH SIDE OF VEHICLE TYPICAL 2 PLACES Figure 9-1 Rear Suspension Assembly and Mounting (Two-Passenger Vehicles) Page 9-2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 83 9. Inspect the bushings (4) and sleeves (3) in the spring eyes and replace them if they are worn or dam- aged. AS SEEN FROM DRIVER-SIDE OF VEHICLE REAR OF VEHICLE Figure 9-2 Support Vehicle on Jack Stands Figure 9-3 Disconnect Brake Cable 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 9-3...

  • Page 84: Leaf Spring Installation (Two-Passenger Vehicles)

    8. Remove the nut (2) and bolt (17) attaching the front of the spring to the vehicle frame and remove the spring. 9. Inspect the bushings (4) and sleeves (3) in the spring eyes and replace them if they are worn or dam- aged. Page 9-4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 85 BRAKE CABLE HANGER MOUNTING REF. TYPICAL ON EACH SIDE OF VEHICLE REF. TYPICAL 2 PLACES REAR OF VEHICLE REF. Figure 9-4 Rear Suspension Assembly and Mounting (Four-Passenger Vehicles) 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 9-5...

  • Page 86: Leaf Spring Installation (Four-Passenger Vehicles)

    2. Tighten the nuts on the U-bolts to 25 ft-lb (34 N·m). 3. Tighten nuts (2) on spring mounting bolts (17) to 15 ft-lb (20.3 N·m) (Figure 9-4, Page 9-5). Page 9-6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 87: Section 10 - Periodic Maintenance

    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 ý...
  • Page 88 • If any problems are found during scheduled inspection or service, do not operate the vehicle until repairs are made. Failure to make necessary repairs could result in fire, property damage, severe personal injury, or death. Page 10-2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 89: Periodic Lubrication Schedule

    Class SE, SF, or SG Oil (or higher) (every 100 hours of Dupont™ Performance Dry Multi-Use operation or 200 rounds Pedal group Lubricant of golf) Figure 10-1 Vehicle Lubrication Points 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 10-3...

  • Page 91: Section 11 - Electrical System And Testing

    Motor braking is automatically disengaged when vehicle speed slows below the programmed top speed. (continued on page 11-7) 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11-1...

  • Page 92: Wiring Diagrams

    (PIN 3) PURPLE: TO LOW SIDE OF POTENTIOMETER (PIN 4) (OPEN) (PIN 5) LT BLUE: POWER DOWN 16-PIN CONNECTOR AT CONTROLLER Figure 11-1 Precedent Electric Vehicle Wiring Diagram Page 11-2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 93 COMPUTER SPADE #6 BLACK TERMINAL #6 BLACK #10 BLACK #6 BLACK NOTE: SOME WIRING / COMPONENTS SHOWN ARE OPTIONAL ACCESSORIES Figure 11-2 Precedent Electric Vehicle Wiring Diagram 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11-3...
  • Page 94 #16 GREY/BLK #16 BROWN/WHITE #16 BROWN/WHITE NORMALLY OPEN MOMENTARY, PUSH BUTTON FOR HORN USED WHEN THERE ARE TURN SIGNALS. Figure 11-3 Precedent Electric Vehicle Accessory Wiring Diagram Page 11-4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 95 SONIC #18 BLUE/WHITE DIODE WELD SONIC WELD NOTE: SOME WIRING / COMPONENTS SHOWN ARE OPTIONAL ACCESSORIES. BRAKE LIGHT RELAY Figure 11-4 Precedent Electric Vehicle Accessory Wiring Diagram 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11-5...
  • Page 96 #18 GREEN REVERSE BUZZER #18 BLACK PROGRAMMER PLUG WARNING LIGHT NOTE: SOME WIRING / COMPONENTS SHOWN ARE OPTIONAL ACCESSORIES Figure 11-5 Precedent Electric Vehicle Instrument Panel Wiring Diagram Page 11-6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 97: 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 98: Troubleshooting Guide 1

    Test Procedure 15 – Forward/Reverse Failed Forward/Reverse rocker switch Rocker Switch on page 11-36 Troubleshooting Guide continued on next page... Page 11-8 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 99 Replace the speed controller. See Speed Failure of the FET that controls the Controller Removal, Section 12, solenoid coil Page 12-11. Troubleshooting Guide continued on next page... 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11-9...
  • Page 100 Failure of the motor armature or brushes 5BC59JBS6365) Replace the speed controller. See Speed Failure of the FET’s that control armature Controller Removal, Section 12, current Page 12-11. Page 11-10 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 101 See Section 15a – Motor (Model Motor Failure 5BC59JBS6365). Replace speed controller. See Speed Speed controller failure Controller Removal, Section 12, Page 12-11. Troubleshooting Guide continued on next page... 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11-11...
  • Page 102 Battery charger connections – loose wires Check wire connections and tighten if at receptacle or batteries necessary. Refer to the appropriate battery charger Battery charger maintenance and service manual. Page 11-12 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 103: Test Procedures

    • Exposure to water may damage electronic components. - Do not operate vehicle without the cover properly installed. - Do not direct a water stream in area of the cover. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11-13...

  • Page 104: Index Of Test Procedures

    48 volts with the batteries fully charged. If not, check for loose battery connec- tions or a battery installed in reverse polarity. Refer to Section 13 – Batteries for further details on battery testing. Page 11-14 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 105 (+) probe (with insulation-piercing probe) on light blue 18-gauge wire at OBC six-pin connector. 5.2. With Tow/Run switch in the RUN position, the voltage reading should be approximately 48 volts. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11-15...
  • Page 106 A reading of 180 to 190 ohms should be obtained (Figure 11-8, Page 11-16). If not, replace the solenoid. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V SOLENOID 2k OHM SETTING Figure 11-8 Activating Coil Test Page 11-16 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 107 16-pin connector at the speed controller. Check terminal positions in three-pin connector at the MCOR and the 16-pin connector. If all of the continuity readings are correct and the connectors are wired correctly, replace the speed controller. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11-17...
  • Page 108 4. As the accelerator pedal is pressed, the voltage reading should increase from approximately 5 volts RMS when the MCOR limit switch closes, to approximately 48 volts RMS with the accelerator pedal fully pressed. Page 11-18 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 109 4. If the reading is below 5 volts with switch in the RUN position, check continuity of the blue 18-gauge wire from the large post of the solenoid to the connector at the Tow/Run switch. 5. If the continuity readings are correct, replace the Tow/Run switch. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11-19...
  • Page 110 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. Page 11-20 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 111 4 negative post and place the red (+) probe (with insulation-piercing probe) on the green wire close to the two-pin connector on the MCOR. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11-21...
  • Page 112 A procedure is provided for testing each of the wires in the 16-pin connector. Refer to the following chart for the appropriate procedure for each pin in the 16-pin connector. Page 11-22 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 113 6. Slowly press the accelerator pedal while monitoring the multimeter. The resistance should rise as the pedal is pressed. When the pedal is all the way to the floor, the multimeter should indicate between 5.67k ohms and 7.43k ohms. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11-23...
  • Page 114 B– terminal of the speed controller (Figure 11-11, Page 11-25). CAUTION • Do not fully insert probes into the 16-pin plug. Doing so can result in a poor connection. Page 11-24 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 115 See WARNING “Lift only one end...” in General Warnings, Section 1, Page 1-2. 3. Disconnect the 16-pin connector at the speed controller. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11-25...
  • Page 116 • Tow/Run switch for proper operation. See Test Procedure 6 – Tow/Run Switch on page 11-19. • Key switch and MCOR limit switch for proper operation. See Test Procedure 8 – Key Switch and MCOR Limit Switch Circuit on page 11-20. Page 11-26 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 117 • Reverse buzzer for proper operation. See Test Procedure 16 – Reverse Buzzer on page 11-37. • Tow/Run switch for proper operation. See Test Procedure 6 – Tow/Run Switch on page 11-19. SPEED CONTROLLER Figure 11-13 Pin 7 Test 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11-27...
  • Page 118 13. If any other reading is obtained, check the following items: • Continuity of the wires in the wire harness • Forward/Reverse switch for proper operation. See Test Procedure 15 – Forward/Reverse Rocker Switch on page 11-36. Page 11-28 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 119 Tighten battery terminals to 110 in-lb (12.4 N·m). 6. With the Tow/Run switch in the TOW position, the multimeter should indicate zero volts. 7. Place the Tow/Run switch in the RUN position. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11-29...
  • Page 120 B– terminal of the speed controller (Figure 11-16, Page 11-31). CAUTION • Do not fully insert probes into the 16-pin plug. Doing so can result in a poor connection. Page 11-30 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 121 • Do not fully insert probes into the 16-pin plug. Doing so can result in a poor connection. 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). 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11-31...
  • Page 122 (full battery voltage). If the reading does not rise from approximately 40 volts to full battery voltage when the DC cord is plugged in and the relay clicks on, check the following items: • Black wire terminal socket in the charger receptacle. Page 11-32 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 123 2. If the reading is zero volts, check the continuity of the 10-gauge red wire from the positive post of battery no. 1 to the receptacle socket. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11-33...
  • Page 124 5.3. If reading is below 3.50 volts, check the continuity of the wires and plug and replace the speed con- troller if necessary. Page 11-34 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 125 Reverse rocker switch in the FORWARD position, and press the accelerator pedal. The solenoid should click and the multimeter should indicate continuity. If the reading is no continuity, replace the solenoid. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11-35...
  • Page 126 5. Place the black (–) probe on the white wire terminal 1 position on the rocker switch and place the red (+) probe on the red wire terminal. With the switch in REVERSE, there should be continuity. If the readings are incorrect, replace the switch. Page 11-36 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 127 3. Place Tow/Run switch in the RUN position. 4. Test drive the vehicle. If the vehicle functions normally the problem is corrected. If the problem still exists, refer to Wiring Diagrams on page 11-2. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11-37...

  • Page 128: Communication Display Module (Cdm)

    See Figure 11-19, Page 11-38 for CDM features. Releasing the button when the desired code is displayed will display the data. Function codes and corresponding data are as fol- lows: Page 11-38 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 129: Using The Cdm To Retrieve Data From The Onboard Computer

    4.2. Drive vehicle a short distance to ensure OBC is not in powerdown mode. 4.3. Check for weak batteries in CDM. 4.4. If reading is still not obtained, go to the CDM Troubleshooting Guide on page 11-40. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11-39...

  • Page 130: 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 131: Section 12 - Electrical Components

    2.2. Rotate the instrument panel up and away from the dash to disengage the tabs at the top of the panel. 2.3. Disconnect the electrical connector (3) to the instrument panel. Figure 12-1 Instrument Panel Removal 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 12-1...
  • Page 132 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 12-2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 133: Battery Warning Light

    See Test Procedure 15, Section 11, Page 11-36. 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. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 12-3...
  • Page 134 REVERSE position. The reverse buzzer will sound as a warning when the Forward/ Reverse switch is in REVERSE. • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. Page 12-4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 135: Electronics Module Cover

    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. ELECTRONICS MODULE TOW/RUN SWITCH BRACKET Figure 12-5 Electronics Module Cover 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 12-5...

  • Page 136: Tow/Run Switch

    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. BLUE PINK Figure 12-6 Tow/Run Switch Page 12-6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 137: Motor Controller Output Regulator (Mcor)

    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. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 12-7...

  • Page 138: Reverse Buzzer

    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. REVERSE BUZZER VIEWED FROM UNDERSIDE OF INSTRUMENT PANEL PINK ORANGE/ WHITE Figure 12-8 Reverse Buzzer Page 12-8 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 139 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 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 12-9...

  • Page 140: Electronics Module

    REVERSE position. The reverse buzzer will sound as a warning when the Forward/ Reverse switch is in REVERSE. • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. Page 12-10 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 141: Solid State Speed Controller

    REVERSE position. The reverse buzzer will sound as a warning when the Forward/ Reverse switch is in REVERSE. • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 12-11...

  • Page 142: Solenoid

    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) and coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion. Page 12-12 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 143: Onboard Computer (Obc)

    Inspect the receptacle for cracks, loose connections and frayed wiring. NOTE: Disassembly of the charger receptacle, for the purpose of removal or installation, is not recom- mended. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 12-13...
  • Page 144 8. 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 12-14 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • 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: Battery Care

    Any frayed or worn wires should be replaced. After all cables have been connected, coat all terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to help prevent future corrosion. Page 13-2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 147: Self-Discharge

    This reduces the battery’s capacity and corrodes the metal parts around it. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 13-3...

  • Page 148: 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 149: 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 150: Battery Troubleshooting Chart

    If discharge time is 60 minutes or If discharge time is less than 60 minutes, more, problem is not with the batteries. replace all batteries below 6.7 volts. Figure 13-3 Battery Troubleshooting Chart Page 13-6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 151: Battery Testing

    4. When the float rises off the bottom, adjust the electrolyte level so that the float rides free of the bottom but does not strike the top of the glass tube. Remove the hydrometer from the cell and release the pres- sure from the bulb. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 13-7...
  • Page 152 When the variations between cells reach 0.050 or more, the battery with the low cell should be replaced. Page 13-8 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 153: Discharge Test

    2. Connect the tester leads to the positive (+) post of battery no.1 and negative (–) post of battery no. 4 (Figure 13-5, Page 13-9). BLACK PROBE TO BATTERY NO. 4 (–) FRONT OF VEHICLE RED PROBE TO BATTERY NO. 1 (+) Figure 13-5 Battery Discharge Test 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 13-9...
  • Page 154 57 Minutes 72 Minutes (21-23 °C) (49-54 °C) 75-79 °F 130-150 °F 60 Minutes 74 Minutes (24-26 °C) (54-66 °C) 80-84 °F 62 Minutes ***** ***** (27-29 °C) Page 13-10 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 155: Battery Troubleshooting Examples

    Battery no. 2 should be replaced with a bat- tery that has the same age and usage as the other batteries in the set. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 13-11...

  • Page 156: 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 157: Section 14 - Battery Charger

    SECTION 14 – BATTERY CHARGER Refer to the appropriate battery charger maintenance and service manual. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 14-1...

  • Page 159: Section 15A - Motor (Model 5Bc59Jbs6365)

    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 160 The motor will need to be removed from the vehicle and repaired by a qualified technician. See Motor Removal on page 15a-3. Page 15a-2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 161: Motor

    (pushing upwards) to move it out of the way (Figure 15a-4, Page 15a-4). 7. Remove the nuts and bolts mounting the rear leaf springs to the shackles. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15a-3...
  • Page 162 8. To remove brush springs (14) from the rigging, lift the spring extensions out and over the brush mounts and then slide the springs off their mounting tabs (Figure 15a-6, Page 15a-5). Page 15a-4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 163: 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 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15a-5...

  • Page 164: Field Windings Inspection

    Burned or scorched insulation on the field windings indicates the motor has overheated due to overloads or grounded or shorted coil windings. If the insulation on the field windings is scorched, replace the motor or the stator shell assembly. Page 15a-6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 165: Motor Components

    Do not remove the bearing from the armature shaft unless it is to be replaced. Figure 15a-8 Brush Spring Tension Test Figure 15a-9 Inspect Bearing 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15a-7...
  • Page 166 MOTOR (MODEL 5BC59JBS6365) Motor Component Testing and Inspection TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 3 PLACES Figure 15a-10 Motor Page 15a-8 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 167: Bearing Removal

    See General Warnings, Section 1, 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. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15a-9...

  • Page 168: Motor Specifications

    Then position the brush springs against the sides of the brushes so that spring pressure will hold them in the retracted position (Figure 15a-6, Page 15a-5). Page 15a-10 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 169 4. Make sure the armature turns freely. If it does not turn freely, disassemble the motor to find the problem. Make sure the bearing is properly seated in the end shield when assembling the motor. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15a-11...

  • Page 170: Motor Installation

    2.5. Using a flat screwdriver, clean the grease out of one of the grooves to allow air to escape when the motor is pushed onto the input shaft. Page 15a-12 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 171 (1.6 mm) gap between the motor adapter ring and transaxle housing as shown (Figure 15a-17, Page 15a-13). 1/16 Inch (1.6 mm) CHAMFER SHAFT END Figure 15a-16 Clean Chamfer and Input Shaft End Figure 15a-17 Gap at Motor and Transaxle 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15a-13...
  • Page 172 REVERSE position. The reverse buzzer will sound as a warning when the Forward/ Reverse switch is in REVERSE. • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. Page 15a-14 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 173: Motor Speed Sensor

    3. Place the Tow/Run switch in the TOW position and connect the batteries, positive (+) cable first. Tighten battery terminals to 110 in-lb (12.4 N·m) and coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15a-15...
  • Page 174 MOTOR (MODEL 5BC59JBS6365) Motor Speed Sensor Motor Speed Sensor Installation, Continued: Figure 15a-20 IQ Motor Speed Sensor Page 15a-16 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 175: Section 15B - Motor (Model Ej4-4001)

    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 IQ 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 176: Motor

    When not performing a test or service procedure that requires movement of the wheels, lock the brakes. Page 15b-2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 177 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. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15b-3...

  • Page 178: Motor Disassembly

    5.1. With the end cap bolts loose (about 1/4 inch between the end cap and the head of the bolt), place a socket on the head of the bolt. See following CAUTION. Page 15b-4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 179 14.2. Use an arbor press to remove the bearing from the end cap. 15. Inspect the bearing for wear and damage. See Bearing Inspection on page 15b-9. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15b-5...

  • Page 180: Motor Component Testing And Inspection

    2. Remove the end cap and armature by performing steps 1 through 7 of Motor Disassembly on page 15b-4. Visual Inspection • Burned, charred or cracked insulation • Improperly cured varnish • Thrown solder • Flared armature windings Page 15b-6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 181 The multimeter should indicate no continuity (Figure 15b-12, Page 15b-7). If the reading is incor- rect, replace the armature. ARMATURE CORE COMMUTATOR Figure 15b-12 Armature Test 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15b-7...

  • Page 182: Motor Frame And Field Windings Inspection

    4. Use dial calipers or a micrometer to measure the brush length. The minimum-allowable brush length is 0.62 inches (16 mm). Replace the set of brushes as required. See preceding NOTE. Page 15b-8 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 183 Figure 15b-14 Bearing Inspection Speed Sensor Magnet Inspection Inspect the speed sensor magnet (24) for rust, wear, and cracks (Figure 15b-15, Page 15b-10). Replace the magnet if necessary. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15b-9...
  • Page 184 Motor Component Testing and Inspection TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 3 PLACES Figure 15b-15 Motor Page 15b-10 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 185: Reconditioning The Motor

    (Figure 15b-15, Page 15b-10). 2.4. Secure the brush rigging to the end cap with two screws. Tighten the screws to 25 in-lb (2.8 N·m) (Figure 15b-10, Page 15b-6). 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15b-11...
  • Page 186 7. Install the speed sensor (10) with screws (25). Tighten to 25 in-lb (2.8 N·m). 8. Make sure the armature turns freely. If it does not turn freely, disassemble the motor to find the problem. Page 15b-12 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 187: Motor Installation

    NOTE: The motor coupling and the new molded bumper must be free of grease and debris. 3.2. Ensure that the installed bumper is seated at the bottom of the coupling. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15b-13...
  • Page 188 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. Page 15b-14 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 189 Reverse switch is in REVERSE. • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. VIEWED FROM DRIVER SIDE Figure 15b-24 Motor Mount 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15b-15...

  • Page 191: Section 16 - Transaxle (Type G)

    • Do not scar or damage the inside surfaces of the tube when removing the oil seal and adapter ring. A damaged tube might have to be replaced. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 16-1...
  • Page 192 Figure 16-1 Axle Tube Figure 16-2 Axle Seal and Adapter Ring Removal ADAPTER RING LIP Figure 16-3 Axle Seal and Adapter Ring Figure 16-4 Axle Seal and Adapter Ring Installation Page 16-2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 193 TRANSAXLE (TYPE G) Axle Bearing and Shaft TYPICAL 6 PLACES Figure 16-5 Transaxle – Type G 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 16-3...

  • Page 194: 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 16-5, Page 16-3). Page 16-4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 195: Transaxle

    Figure 16-6 Vehicle Supported on Jack Stands Figure 16-7 Brake Cable Remove bolt, then rotate shackle up and away from spring. Figure 16-8 Disconnect Shocks Figure 16-9 Shackles 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 16-5...
  • Page 196 NOTE: Recycle or dispose of used oil or lubricant in accordance with local, state, and federal regulations. 16. Remove the brake assemblies if required. See Brake Cluster Removal, Section 6, Page 6-9. Page 16-6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 197: Transaxle Disassembly, Inspection, And Assembly

    6. To disassemble the intermediate gear assembly, press off together the bearing (16) and the gear (19) (Figure 16-5, Page 16-3). See also Figure 16-13, Page 16-8. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 16-7...
  • Page 198 8.4. Remove the differential pin (31) by pushing pin through differential gear case from one side (Figure 16-5, Page 16-3). See also Figure 16-15, Page 16-9. 8.5. Remove the idler gears and thrust plates (1 and 2) (Figure 16-16, Page 16-9). Page 16-8 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...

  • Page 199: Transaxle Assembly

    6. Install the differential assembly, the intermediate gear assembly, and the input pinion gear simulta- neously. Be sure all bearings are seated properly in the housing. Rotate the input shaft to check for smooth gear operation (Figure 16-11, Page 16-6). 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 16-9...

  • Page 200: Transaxle Installation

    2. Align the center hole in the saddle of the transaxle with the pilot bolt in the leaf spring assembly. Page 16-10 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 201 REVERSE position. The reverse buzzer will sound as a warning when the Forward/ Reverse switch is in REVERSE. • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 16-11...
  • Page 203 ..............13-7 testing ............11-33 on-charge voltage test .........13-7 charger receptacle bezel battery warning light installation ............4-7 installation ............12-3 removal ..............4-7 removal ............12-3 cleaning testing ............11-38 brake assembly ..........6-5 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page i-1...
  • Page 204 ........15a-5, 15b-6 high pedal detect ..........11-7 assembly ........15a-10, 15b-11 bearing inspection ........15a-7, 15b-9 installation ..........15a-9 inspection front wheel free play ........7-17 removal ............. 15a-9 Page i-2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 205 ........11-15, 11-32, 11-33 seat back (four-passenger) installation ............4-13 removal ............4-12 pawl assembly ............5-4 seat support (four-passenger) pedal group installation ............4-13 installation ............5-6 removal ..............5-1 removal ............4-13 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page i-3...
  • Page 206 8 – key switch ..........11-20 suspension, front 8 – MCOR limit switch ........11-20 camber adjustment .......... 7-10 9 – 16-pin connector ........11-22 Page i-4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 207 ...........16-2 removal ............16-1 removal ............16-5 troubleshooting ..........11-2 battery troubleshooting examples ....13-11 communication display module (CDM) ..11-40 troubleshooting guide 1 ........11-8 troubleshooting guide 2 ........11-11 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page i-5...

  • Page 208: Section I - Index

    3. Clarity of Illustrations 4. Index Usability 5. Troubleshooting Chart Usability Comments/Suggestions Please fax a copy of this page to (706) 228-2662. Thank You! Club Car Technical Publication Department 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual...
  • Page 209 Club Car NOTES...
  • Page 210 Club Car NOTES...
  • 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...

Table of Contents