Page 1 2009 Electric Precedent Maintenance and Service Manual IQ System and Excel System Vehicles Manual Number 103472701 Edition Code 0309A00000...
Page 3 If it appears that a service question is not answered in this manual, please contact your nearest authorized Club Car dealer or distributor for assistance. You may also write to us at: Club Car, Inc., P.O. Box 204658; Augusta, GA 30917–4658 USA, Attention: Technical Services.
Page 5: Table Of Contents
SECTION 5 — ACCELERATOR AND BRAKE PEDAL GROUP ................5-1 Pedal Group..............................5-1 Pedal Group Removal..........................5-1 Throttle Position Sensor ..........................5-3 Debris Shields ............................5-3 Accelerator Pedal Removal ........................5-3 2009 Electric Precedent Maintenance and Service Manual Page iii...
Page 6 SECTION 8 — WHEELS AND TIRES ......................... 8-1 General Information ............................8-1 Wheels ................................. 8-1 Wheel Removal ............................8-1 Wheel Installation ............................8-1 Tires ................................8-2 Tire Removal............................. 8-2 Tire Repair ..............................8-2 Tire Installation ............................8-3 Page iv 2009 Electric Precedent Maintenance and Service Manual...
Page 7 Functions ..............................13-4 Information.............................. 13-4 Programmer Setup ..........................13-4 Monitor Menu .............................. 13-4 Throttle ..............................13-4 Batt Voltage............................. 13-5 Heatsink..............................13-5 Arm Current ............................13-5 Field Current ............................13-5 Arm PWM ............................... 13-5 2009 Electric Precedent Maintenance and Service Manual Page v...
Page 8 Menu Navigation ............................14-2 Program (IQDM-P only) ........................... 14-3 Monitor ..............................14-3 Faults ..............................14-4 Functions ..............................14-4 Information.............................. 14-4 Programmer Setup ..........................14-4 Monitor Menu .............................. 14-4 Speed ..............................14-5 Throttle ..............................14-5 Page vi 2009 Electric Precedent Maintenance and Service Manual...
Page 9 SECTION 15 — ELECTRICAL COMPONENTS ....................15-1 Key Switch ..............................15-1 Testing the Key Switch ..........................15-1 Key Switch Removal ..........................15-1 Key Switch Installation ..........................15-1 Battery Warning Light........................... 15-2 Testing the Battery Warning Light......................15-2 2009 Electric Precedent Maintenance and Service Manual Page vii...
Page 10 Discharge Test ............................16-12 Battery Troubleshooting Examples......................16-14 Battery Replacement ..........................16-15 Battery Care...............................16-16 Battery Care – Vehicles Equipped with the Single-Point Watering System ..........16-16 Battery Care – Vehicles Without the Single-Point Watering System............16-17 Page viii 2009 Electric Precedent Maintenance and Service Manual...
Page 11 Fast Accel ............................... 20-3 Pedal Up Mode............................20-3 Speed Cal ............................... 20-3 Code A, Code B, and Code C........................20-3 Slow Pedal Up............................20-4 KSI SRO Enable............................20-4 M2 Max Speed ............................20-4 2009 Electric Precedent Maintenance and Service Manual Page ix...
Page 12 Pedal Up Mode............................21-3 Speed Cal ............................... 21-3 S3 FWD Speed ............................21-4 Code A, Code B, and Code C........................21-4 Vehicle S/N ............................. 21-4 Vehicle Decal ............................21-4 SECTION i — INDEX Page x 2009 Electric Precedent Maintenance and Service Manual...
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 CAUTION.
Page 14 • To avoid unintentionally starting the vehicle, disconnect the batteries as shown (Figure 1-1, Page 1-3) and (Figure 1-2, Page 1-3). • After disconnecting the batteries, wait 90 seconds for the controller capacitors to discharge. • Do not leave children unattended on vehicle. Page 1-2 2009 Electric Precedent Maintenance and Service Manual...
Page 15 Connect battery cables in reverse order. Connect battery cables in reverse order. Figure 1-1 Battery Cable Removal – 4 x 12 Volt Battery Figure 1-2 Battery Cable Removal – 6 x 8 Volt Battery Configuration Configuration 2009 Electric Precedent Maintenance and Service Manual Page 1-3...
Page 17: Section 2 - Vehicle Specifications
17 ft - 4in. (528 cm) 17 ft - 4 in. (528 cm) Standard seating capacity LIQUID CAPACITIES 22 oz. 22 oz. Transaxle (.67 liters) (.67 liters) TABLE CONTINUED ON NEXT PAGE 2009 Electric Precedent Maintenance and Service Manual Page 2-1...
Page 18 General Warnings VEHICLE SPECIFICATIONS TWO- FOUR- PASSENGER PASSENGER SPECIFICATIONS ELECTRIC ELECTRIC VEHICLE VEHICLE TIRE PRESSURE 18-20 psi (1.24-1.38 18-20 psi (1.24-1.38 Front and rear bars) bars) Page 2-2 2009 Electric Precedent Maintenance and Service Manual...
Page 19: Section 3 - General Information
• See General Warnings on page 1-1. Important features unique to the different models covered in this manual are highlighted. Club Car, Inc. recommends the owner/operator read and understand this manual and pay special attention to features specific to their vehicle(s).
Page 20: Safety Committee
This is to prevent unintentionally starting the vehicle or a fire hazard. • Do not attempt to charge frozen batteries or batteries with bulged cases. Discard the battery. Frozen batteries can explode. Page 3-2 2009 Electric Precedent Maintenance and Service Manual...
Page 21: Preparing The Electric Vehicle For Extended Off-Season Storage
• Do not attempt to charge frozen batteries or batteries with bulged cases. Discard the battery. Frozen batteries can explode. Adjust tire to recommended pressure. See Section 2 — Vehicle Specifications . Perform the Pre-Operation and Daily Safety Checklist. See Owner’s Manual. 2009 Electric Precedent Maintenance and Service Manual Page 3-3...
Page 23: 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 24: Front And Rear Body Repair
Continue heating and bending the body until the original shape returns. Under no circumstance should the gun be held closer than 6 inches (15 cm) to the body. See preceding CAUTION. Page 4-2 2009 Electric Precedent Maintenance and Service Manual...
Page 25: Minor Scratches And Surface Blemishes
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). Tighten screws to 25 in-lb (2.8 N·m). 2009 Electric Precedent Maintenance and Service Manual Page 4-3...
Page 26 Front Body BODY AND TRIM Figure 4-1 Front Body Page 4-4 2009 Electric Precedent Maintenance and Service Manual...
Page 27: Front Bumper
The front bumper (3) is attached to the vehicle frame rails by nuts (5) and bolts (4). The nuts (5) need to go on top of the bumper attaching brackets, always insert the bolts (4) through the bottom. The nuts are tightened to 13.3 ft-lb (18 N·m). Figure 4-2 Bracket and Front Bumper 2009 Electric Precedent Maintenance and Service Manual Page 4-5...
Page 28: Instrument Panel
Ensure that there are no wires exposed or pinched during positioning. 2.3. Secure instrument panel to the dash assembly with screws (1 and 2). Tighten screws to 1.8 ft-lb (2.5 N·m). Figure 4-3 Instrument Panel Page 4-6 2009 Electric Precedent Maintenance and Service Manual...
Page 29: Floor Mat And Retainers
Ensure the floor mat is properly positioned beneath the top flange of the retainer and loosely install two screws (2). Install two push rivets (4) at the rear corners of the retainer. Tighten screws (2) to 4.4 ft-lb (6.0 N·m). 2009 Electric Precedent Maintenance and Service Manual Page 4-7...
Page 30: Kick Plate And Charger Receptacle Bezel
Install two front screws (3) to secure the rear beauty panel. Tighten screws to 3.7 ft-lb (5 N·m). Install floor mat. See Floor Mat and Retainers on page 4-7. Snap charger bezel (4) in place on the kick plate. Figure 4-5 Kick Plate and Charger Receptacle Bezel Page 4-8 2009 Electric Precedent Maintenance and Service Manual...
Page 31: Rear Body - Two-Passenger Vehicles
The sweater basket (11) is secured to the bag hoop assembly by three screws (12). Tabs on the upper edge of the basket align with holes in the bag hoop (6) for installation purposes. Tighten screws (12) to 4.8 ft-lb (6.5 N·m) to secure the sweater basket (Figure 4-7, Page 4-10). 2009 Electric Precedent Maintenance and Service Manual Page 4-9...
Page 32 Rear Body – Two-Passenger Vehicles BODY AND TRIM Figure 4-7 Backrest and SAM Page 4-10 2009 Electric Precedent Maintenance and Service Manual...
Page 33: Rear Body Components (Two-Passenger)
Wheel Liner Installation Position liners (8 and 9) on vehicle and secure with bolts (10). Bolts (10) thread into J-clips (11) attached to the inner-frame rail. Tighten bolts to 4.4 ft-lb (6 N·m). 2009 Electric Precedent Maintenance and Service Manual Page 4-11...
Page 34 Rear Body – Two-Passenger Vehicles BODY AND TRIM * Two-Passenger Vehicles Only Figure 4-8 Rear Body Components Page 4-12 2009 Electric Precedent Maintenance and Service Manual...
Page 35: Rear Body - Four-Passenger Vehicles
Remove screws (8 and 11) securing the rear hip restraints (6) and remove the hip restraints from the vehicle (Figure 4-10, Page 4-14). Remove the screws (5) and bolts (4) from the seat support (3) and remove the seat support from the vehicle. 2009 Electric Precedent Maintenance and Service Manual Page 4-13...
Page 36: Foot Deck
Remove the four bolts (2) securing the foot deck (1) to the vehicle frame (Figure 4-11, Page 4-15). Foot Deck Installation Install foot rest in reverse order of removal. Tighten bolts (2) to 71 in-lb (8 N·m) (Figure 4-11, Page 4-15). Page 4-14 2009 Electric Precedent Maintenance and Service Manual...
Page 37: Rear Body Components (Four-Passenger)
Access panel (6) is secured to the rear underbody (4) with two push rivets (7) (Figure 4-8, Page 4-12). When replacing the panel, insert push rivets (7) to hold the panel in place. Rear Underbody Removal Remove four screws (5) attaching the rear underbody (4) to vehicle (Figure 4-8, Page 4-12). 2009 Electric Precedent Maintenance and Service Manual Page 4-15...
Page 38: Canopy - Two-Passenger
Remove two bolts (11) from each front canopy support (7 and 10) and remove canopy supports from the vehicle. Remove two bolts (6) from each rear support (3) and pull rear supports from vehicle. Page 4-16 2009 Electric Precedent Maintenance and Service Manual...
Page 39 BODY AND TRIM Canopy – Two-Passenger Figure 4-12 Precedent Two-Passenger Canopy 2009 Electric Precedent Maintenance and Service Manual Page 4-17...
Page 40: Two-Passenger Canopy Installation
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 2009 Electric Precedent Maintenance and Service Manual...
Page 41 BODY AND TRIM Canopy – Two-Passenger Figure 4-13 Precedent Four-Passenger Canopy 2009 Electric Precedent Maintenance and Service Manual Page 4-19...
Page 42: Canopy - Four-Passenger
Tighten the four bolts (2) installed in step 1.2 to 18 ft-lb (25 N·m). Secure each front support cover (4) with one screw (5). Tighten the hardware to 53 in-lb (6 N·m). Page 4-20 2009 Electric Precedent Maintenance and Service Manual...
Page 43: Section 5 - Accelerator And Brake Pedal Group
NOTE: Nut (4) has a left-hand thread. Loosen turnbuckle (6) until the threaded rod (8) from the pedal group (11) is free of the turnbuckle (Figure 5-2, Page 5-2). Figure 5-1 Pedal Group Access 2009 Electric Precedent Maintenance and Service Manual Page 5-1...
Page 44 Remove two screws (2) on the driver side of the pedal group and two screws (1) on the passenger side of the pedal group. Disconnect six-pin connector (12) from throttle position sensor. Lift pedal group from vehicle. Page 5-2 2009 Electric Precedent Maintenance and Service Manual...
Page 45: Throttle Position Sensor
(13) (Figure 5-3, Page 5-4). Tighten screws (13) to 38 in-lb (4.3 N·m) Install debris shields (4 and 5). Install pedal group in vehicle. See Pedal Group Installation on page 5-5. 2009 Electric Precedent Maintenance and Service Manual Page 5-3...
Page 46 Pedal Group ACCELERATOR AND BRAKE PEDAL GROUP 000487-002 Figure 5-3 Accelerator Pedal Assembly and Brake Pedal Assembly Page 5-4 2009 Electric Precedent Maintenance and Service Manual...
Page 47: Brake Pedal Removal
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). 2009 Electric Precedent Maintenance and Service Manual Page 5-5...
Page 49: 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 components. 2009 Electric Precedent Maintenance and Service Manual Page 6-1...
Page 50 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). 2400-23600-10221 Figure 6-3 Remove Axle Retaining Ring Page 6-2 2009 Electric Precedent Maintenance and Service Manual...
Page 51 10. Grasp both brake shoes and pull them, together with the springs, out of the brake assembly as shown (Figure 6-6, Page 6-4). 11. Remove adjuster wheel (1) with two washers (2 and 3) from the backing plate (Figure 6-7, Page 6-4). 2009 Electric Precedent Maintenance and Service Manual Page 6-3...
Page 52 Brake Shoe Removal WHEEL BRAKE ASSEMBLIES 1400-18100-10222 1400-17700-10225 Figure 6-5 Remove Shoe Retainer Clip Figure 6-6 Remove Brake Shoes Figure 6-7 Remove Adjuster Wheel Figure 6-8 Lubricate Slide and Slide Plate Page 6-4 2009 Electric Precedent Maintenance and Service Manual...
Page 53: Brake Assembly Cleaning
(Figure 6-11, Page 6-6). See preceding WARNING. Install the adjuster wheel (1) and two washers (2 and 3) into the adjuster assembly (Figure 6-7, Page 6-4). 2009 Electric Precedent Maintenance and Service Manual Page 6-5...
Page 54 Brake Assembly Cleaning WHEEL BRAKE ASSEMBLIES Figure 6-11 Apply Grease To Brake Adjuster Figure 6-12 Install Adjuster Wheel, Trailing Shoe Page 6-6 2009 Electric Precedent Maintenance and Service Manual...
Page 55: Brake Shoe Installation
After the shoes are installed, move them together up and down and side to side to make sure that they will easily slide approximately 1/4 to 3/8 inch (6.3 to 9.5 mm) without binding (Figure 6-16, Page 6-8). 2009 Electric Precedent Maintenance and Service Manual Page 6-7...
Page 56 7.3. 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 and CAUTION. Page 6-8 2009 Electric Precedent Maintenance and Service Manual...
Page 57 11. Adjust brake cable equalizer. See Brake Cable Equalizer Adjustment on page 6-10. Figure 6-18 Equalizer Adjustment 2009 Electric Precedent Maintenance and Service Manual Page 6-9...
Page 58: Brake Cable Equalizer Adjustment
6.2. 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 6-10 2009 Electric Precedent Maintenance and Service Manual...
Page 59: Brake Cluster Removal And Installation
(Figure 6-4, Page 6-3). Tighten nuts to 17 ft-lb (23.0 N·m). If torquing the bolt heads, torque to 30 ft-lb (40.6 N·m). Install the rear axle onto the transaxle. See following NOTE. 2009 Electric Precedent Maintenance and Service Manual Page 6-11...
Page 60 Tighten lug nuts on rear wheels, using a crisscross pattern, to 55 ft-lb (74.6 N·m) for steel wheels or 65 ft-lb (88 N·m) for alloy mag wheels. See Wheel Installation on page 8-1. Adjust the brakes. See Brake Cable Equalizer Adjustment on page 6-10. Page 6-12 2009 Electric Precedent Maintenance and Service Manual...
Page 61: Brake Cable Removal And Installation
(1) is a left-hand thread. Thread each nut approximately 1/2 inch (12.7 mm) away from the turnbuckle. Loosen turnbuckle (2) until the bolt (5) is free of the turnbuckle. 2009 Electric Precedent Maintenance and Service Manual Page 6-13...
Page 62: Brake Cable Installation
• 2009 model year Precedent vehicles had a running change in brake cable design (Figure 6-19, Page 6-13). Never mix components of the different designs. See NOTE at beginning of this section. Page 6-14 2009 Electric Precedent Maintenance and Service Manual...
Page 63 Place tab (3) on cable housing over the forward leaf spring mounting bolt (2) (Figure 6-22, Page 6-14). Install nut (1). Tighten nut to 18.4 ft-lb (25 N·m). Adjust the brakes. See Brake Cable Equalizer Adjustment on page 6-10. 2009 Electric Precedent Maintenance and Service Manual Page 6-15...
Page 65: Section 7 - Steering And Front Suspension
6.5. Remove the steering wheel puller. 6.6. Remove the steering wheel bolt (6) and the steering wheel (7) from the steering column (9) (Figure 7-3, Page 7-3). 2009 Electric Precedent Maintenance and Service Manual Page 7-1...
Page 66: Steering Wheel Installation
Loosen the bolt (11) that attaches the steering column universal joint to the stud on the steering gear (Figure 7-3, Page 7-3). Remove the four bolts (10) that attach the steering column to the frame. Remove the steering column from the vehicle. Page 7-2 2009 Electric Precedent Maintenance and Service Manual...
Page 67: Steering Column Installation
Figure 7-3 Steering Column STEERING COLUMN INSTALLATION For ease of assembly and to prevent corrosion, apply a light coat of anti-seize or lubricating compound to the splined stud extending from the steering gear. 2009 Electric Precedent Maintenance and Service Manual Page 7-3...
Page 68: Rack And Pinion
Remove the three bolts (5) from the steering rack and pinion assembly mounting bracket. Remove the bolt (6) from the universal joint, then remove the rack and pinion assembly and universal joint from the vehicle. Page 7-4 2009 Electric Precedent Maintenance and Service Manual...
Page 69: Rack And Pinion Disassembly
12. Inspect the ball joints (8) for wear. If one or both of the ball joints (8) are excessively worn, remove and replace the ball joint from the rack (18). 13. Remove the rack (18) from housing (17). 2009 Electric Precedent Maintenance and Service Manual Page 7-5...
Page 70 Rack and Pinion STEERING AND FRONT SUSPENSION Figure 7-5 Steering Gear Page 7-6 2009 Electric Precedent Maintenance and Service Manual...
Page 71: Rack And Pinion Assembly
Install pinion (5) and bearing (4) assembly into the housing (17). Make sure the rack gear teeth will mesh with the gear teeth on the pinion. The rack may need to be rotated slightly while lightly tapping on the pinion-bearing assembly with a rubber mallet. See following CAUTION. 2009 Electric Precedent Maintenance and Service Manual Page 7-7...
Page 72: Rack And Pinion Installation
• Do not operate vehicle until toe-in is adjusted and ball joints are secured. Adjust the toe-in. See Toe-in Adjustment on page 7-11. Test drive vehicle before returning it to service. Page 7-8 2009 Electric Precedent Maintenance and Service Manual...
Page 73 STEERING AND FRONT SUSPENSION Rack and Pinion Figure 7-10 Press In Dust Seal Figure 7-11 Install Ball Joint Figure 7-12 Rack and Pinion Adjustment Figure 7-13 Rack and Pinion Resistance 2009 Electric Precedent Maintenance and Service Manual Page 7-9...
Page 74: Front Suspension
7-16) to 37 ft-lb (50 N·m). Then roll the vehicle forward one full tire revolution and recheck the camber. See also Figure 7-14, Page 7-11. 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 2009 Electric Precedent Maintenance and Service Manual...
Page 75 Subtract the measurement on the front of the tires from the measurement on the rear of the tires. The difference is the toe-in. Proper toe-in is 3/8 inch ± 1/8 inch (9.5 mm ± 3.2mm). If adjustment is necessary, proceed as follows: 2009 Electric Precedent Maintenance and Service Manual Page 7-11...
Page 76: Front Suspension Components
Install tie rod ends (12) into the spindle tabs. Install the retaining nuts (14) (Figure 7-18, Page 7-15). Adjust wheel toe-in. See Toe-in Adjustment on page 7-11. Page 7-12 2009 Electric Precedent Maintenance and Service Manual...
Page 77: Leaf Spring Removal
10. Inspect the bushings (4). If the bushings are worn or damaged, remove them and press in new ones. KINGPIN AND STEERING SPINDLE INSTALLATION Inspect all parts and replace them as necessary. 2009 Electric Precedent Maintenance and Service Manual Page 7-13...
Page 78: Control Arm Removal
SHOCK ABSORBER INSTALLATION NOTE: When installing shock absorbers, make sure front shocks have identical part numbers. Install the shock absorber by reversing the removal procedure. Tighten the bolts to 16 ft-lb (21 N·m). Page 7-14 2009 Electric Precedent Maintenance and Service Manual...
Page 79 STEERING AND FRONT SUSPENSION Front Suspension Components 1311 Figure 7-18 Upper Front Suspension Assembly 2009 Electric Precedent Maintenance and Service Manual Page 7-15...
Page 80 Front Suspension Components STEERING AND FRONT SUSPENSION 1312 Figure 7-19 Lower Front Suspension Assembly Page 7-16 2009 Electric Precedent Maintenance and Service Manual...
Page 81: Front Wheel Bearings And Hubs
Install wheels and finger-tighten lug nuts. Lower the vehicle and finish tightening lug nuts, using a crisscross pattern, to 55 ft-lb (74.6 N·m) for steel wheels or 65 ft-lb (88 N·m) for alloy mag wheels. 2009 Electric Precedent Maintenance and Service Manual Page 7-17...
Page 82 Front Wheel Bearings and Hubs STEERING AND FRONT SUSPENSION Figure 7-20 Front Wheel Hub Page 7-18 2009 Electric Precedent Maintenance and Service Manual...
Page 83: Section 8 - Wheels And Tires
Install wheel(s) and tighten the lug nuts, using a crisscross pattern, until they are snug. Lower the vehicle and finish tightening lug nuts, using a crisscross pattern, to 55 ft-lb (74.6 N·m) for steel wheels or 65 ft-lb (88 N·m) for alloy mag wheels. 2009 Electric Precedent Maintenance and Service Manual Page 8-1...
Page 84: Tires
1.1. Remove the wheel. See Wheel Removal on page 8-1. Inflate the tire to no more than 20 psi (1.38 Bars). 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 2009 Electric Precedent Maintenance and Service Manual...
Page 85: Tire Installation
Quickly remove the air nozzle and install the valve core. Adjust air pressure in tire to recommended pressure. See Section 2 — Vehicle Specifications . Immerse the wheel and tire assembly in water to make sure there are no leaks. 2009 Electric Precedent Maintenance and Service Manual Page 8-3...
Page 86 Tires WHEELS AND TIRES Figure 8-2 Inflate Tire Page 8-4 2009 Electric Precedent Maintenance and Service Manual...
Page 87: Section 9 - Rear Suspension
SHOCK ABSORBER INSTALLATION To install, reverse the removal procedure. On the upper and lower shock absorber mounting stems, tighten the nuts until the rubber bushing expands to the size of the cup washer. 2009 Electric Precedent Maintenance and Service Manual Page 9-1...
Page 88: Leaf Springs (Two-Passenger Vehicles)
Remove the nut (2) and bolt (17) attaching the front of the spring to the vehicle frame and remove the spring. 10. Inspect the bushings (4) and sleeves (3) in the spring eyes and replace them if they are worn or damaged. Page 9-2 2009 Electric Precedent Maintenance and Service Manual...
Page 89: Leaf Spring Installation (Two-Passenger Vehicles)
Tighten the nuts on the U-bolts to 25 ft-lb (34 N·m) and tighten nuts (2) on spring mounting bolts (17) to 15 ft-lb (20.3 N·m) (Figure 9-3, Page 9-4). Install tire and wheel assembly. See Wheel Installation, Section 8, Page 8-1. 2009 Electric Precedent Maintenance and Service Manual Page 9-3...
Page 90: Leaf Springs (Four-Passenger Vehicles)
LEAF SPRING REMOVAL (FOUR-PASSENGER VEHICLES) Disconnect the battery cables and discharge the controller as instructed. See WARNINGS “To avoid unintentionally starting...” and “After disconnecting the batteries, wait 90 seconds...” in General Warnings on page 1-1. Page 9-4 2009 Electric Precedent Maintenance and Service Manual...
Page 91: Leaf Spring Installation (Four-Passenger Vehicles)
Tighten the nuts on the U-bolts to 25 ft-lb (34 N·m) and tighten nuts (2) on spring mounting bolts (17) to 15 ft-lb (20.3 N·m) (Figure 9-4, Page 9-6). Install tire and wheel assembly. See Wheel Installation, Section 8, Page 8-1. 2009 Electric Precedent Maintenance and Service Manual Page 9-5...
Page 92 Leaf Springs (Four-Passenger Vehicles) REAR SUSPENSION Figure 9-4 Rear Suspension Assembly and Mounting (Four-Passenger Vehicles) Page 9-6 2009 Electric Precedent Maintenance and Service Manual...
Page 93: Section 10 - Periodic Maintenance
• Moving parts! Do not attempt to service the vehicle while it is running. • Hot! Do not attempt to service hot motor. Failure to heed this warning could result in severe burns. WARNING CONTINUED ON NEXT PAGE 2009 Electric Precedent Maintenance and Service Manual Page 10-1...
Page 94 Connect battery cables in reverse order. Connect battery cables in reverse order. Figure 10-1 Battery Cable Removal – 4 x 12 Volt Battery Figure 10-2 Battery Cable Removal – 6 x 8 Volt Battery Configuration Configuration Page 10-2 2009 Electric Precedent Maintenance and Service Manual...
Page 95: General Information
Any vehicle not functioning correctly should be removed from use until it is properly repaired. This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service. PERIODIC SERVICE SCHEDULE WARNING •...
Page 96 (every 100 hours of operation or 200 rounds all cells to verify correct valve operation. See Single Point Watering System) of golf) Battery Care on page 16-16. TABLE CONTINUED ON NEXT PAGE Page 10-4 2009 Electric Precedent Maintenance and Service Manual...
Page 97 (every 100 hours of operation or 200 rounds Lubricate all rotating joints. See Periodic Pedal group of golf) Lubrication Schedule on page 10-6. General Vehicle Check for loose hardware; tighten if necessary. 2009 Electric Precedent Maintenance and Service Manual Page 10-5...
Page 98: Periodic Lubrication Schedule
Annually by trained technician SE, SF, or SG Oil (or higher) only (every 100 hours of Dupont™ Performance Dry Multi-Use operation or 200 rounds of golf) Pedal group Lubricant Figure 10-3 Vehicle Lubrication Points Page 10-6 2009 Electric Precedent Maintenance and Service Manual...
Page 99: Section 11 - Iq System Troubleshooting
• Pedal Down Motor Braking: This feature helps to control vehicle downhill speed. Motor braking is activated when the vehicle reaches the programmed top speed and holds the vehicle at that speed. Motor braking is automatically disengaged when vehicle speed slows below the programmed top speed. 2009 Electric Precedent Maintenance and Service Manual Page 11-1...
Page 100: Wiring Diagrams
4 - PIN CONNECT O R A T CONTR OLLER 16 - PIN CON NECT OR A T CONT ROLLER WD1034969-5-L COM M UNICA T ION PORT Figure 11-1 Wiring Diagram – IQ System Page 11-2 2009 Electric Precedent Maintenance and Service Manual...
Page 101 IQ SYSTEM TROUBLESHOOTING Wiring Diagrams WD1034969-5-R Figure 11-2 Wiring Diagram – IQ System (Continued) 2009 Electric Precedent Maintenance and Service Manual Page 11-3...
Page 102 #16 GRAY #16 BROWN/WHITE #16 BROWN/WHITE NORMALLY OPEN MOM ENTARY, PUSH BU TTON FOR HORN USED WHEN THERE ARE TURN S IGNALS. WD1025104E5-L Figure 11-3 Precedent Electric Vehicle Accessory Wiring Diagram Page 11-4 2009 Electric Precedent Maintenance and Service Manual...
Page 103 SON IC #18 BLUE/WHITE DIODE WELD SO NIC WELD NOTE: SOME WIRING / COMPONENTS SHOWN ARE OPTIONAL ACCESSORIES. BRAKE LIGHT RELAY WD1025104E5-R Figure 11-4 Precedent Electric Vehicle Accessory Wiring Diagram (Continued) 2009 Electric Precedent Maintenance and Service Manual Page 11-5...
Page 104 #18 GREEN REVERS E BUZZER #18 BLACK PRO GRAMMER PLUG WARNING LIGHT NOTE: SOME WIRING / COMPONENTS S HOWN ARE OPTIONAL ACCESSORIES WD1025104E6 Figure 11-5 Precedent Electric Vehicle Instrument Panel Wiring Diagram Page 11-6 2009 Electric Precedent Maintenance and Service Manual...
Page 105: Troubleshooting
(17.7 km/h), with the accelerator pedal still released, motor braking will be deactivated and the vehicle will coast freely. This feature is selectable. Contact your Club Car dealer/distributor to inquire about this selectable feature. • Regenerative Braking: When motor braking is activated, the vehicle motor acts as a generator, slowing the vehicle as it creates energy that is used to charge the batteries.
Page 106: Troubleshooting Guide 1
IQ SYSTEM TROUBLESHOOTING Club Car recommends the use of the IQDM handset for troubleshooting vehicles equipped with the IQ electrical system. Troubleshooting Guide 1 is to be used in conjunction with the IQDM handset. See Section 13 — IQ Display Module (IQDM) and IQDM-P Diagnostics: IQ System for operating instructions.
Page 107 Repair and/or connect the 16-pin connector code speed controller or broken wire to the speed controller Test Procedure 4 – Throttle Position Sensor Failed throttle position sensor Voltage on page 11-16 TABLE CONTINUED ON NEXT PAGE 2009 Electric Precedent Maintenance and Service Manual Page 11-9...
Page 108 Section 18 — Motor (Model EJ4-4001 and Failure of the motor armature or brushes code EJ8-4001A) Failure of the FET’s that control armature Replace the speed controller. See Speed current Controller Removal on page 15-12. Page 11-10 2009 Electric Precedent Maintenance and Service Manual...
Page 109: Troubleshooting Guide 2
Cycle accelerator pedal Section 18 — Motor (Model EJ4-4001 and Motor Failure EJ8-4001A) Replace speed controller. See Speed Speed controller failure Controller Removal on page 15-12. TABLE CONTINUED ON NEXT PAGE 2009 Electric Precedent Maintenance and Service Manual Page 11-11...
Page 110 Battery charger connections – loose wires at Check wire connections and tighten if charge batteries receptacle or batteries necessary. Refer to the appropriate battery charger Battery charger maintenance and service manual. Page 11-12 2009 Electric Precedent Maintenance and Service Manual...
Page 111: Test Procedures
16 – Pin 10 17 – Pin 12 18 – Onboard Computer Silicon-Controlled Rectifier (SCR) Circuit 19 – Onboard Computer Gray Wire 20 – Voltage at Charger Receptacle Red Wire Socket 2009 Electric Precedent Maintenance and Service Manual Page 11-13...
Page 112 2. BLACK probe to battery no. 4 (-). Figure 11-6 Battery Voltage Test – 4 x 12 Volt Battery Figure 11-7 Battery Voltage Test – 6 x 8 Volt Battery Configuration Configuration Page 11-14 2009 Electric Precedent Maintenance and Service Manual...
Page 113 Place red (+) probe of the multimeter on the positive (+) solenoid terminal. Place the black (–) probe on the other small solenoid terminal. A reading of 180 to 190 ohms should be obtained (Figure 11-8, Page 11-16). If not, replace the solenoid. 2009 Electric Precedent Maintenance and Service Manual Page 11-15...
Page 114 If reading is zero volts, check the black/white wire continuity from the six-pin connector at the throttle position sensor to the 16-pin connector at the speed controller. Check terminal positions in six-pin connector at the throttle Page 11-16 2009 Electric Precedent Maintenance and Service Manual...
Page 115 Also, check continuity of all motor wires. See Section 18 — Motor (Model EJ4-4001 and EJ8-4001A) . TEST PROCEDURE 6 – Tow/Run Switch See General Warnings on page 1-1. Tow/Run Switch Test with the IQDM Handset 2009 Electric Precedent Maintenance and Service Manual Page 11-17...
Page 116 Connect the tester leads to the positive (+) post of battery no.1 and negative (–) post of battery no. 4 (Figure 11-9, Page 11-19)) or battery no. 6 (Figure 11-10, Page 11-19). Page 11-18 2009 Electric Precedent Maintenance and Service Manual...
Page 117 Testing battery voltage while the batteries are not under load will not always indicate the true condition of the batteries. For more information about the batteries, refer to Section 16 — Batteries . 2009 Electric Precedent Maintenance and Service Manual Page 11-19...
Page 118 4.3. With the key switch in the OFF position, the multimeter should indicate that continuity is not present. 4.4. With the key switch in the ON position, the multimeter should indicate that continuity is present. Page 11-20 2009 Electric Precedent Maintenance and Service Manual...
Page 119 When connecting the 16-pin connector to the controller, push plug into controller receptacle with enough force to lock plug into place. An audible click will be heard when plug is properly seated to the controller. 2009 Electric Precedent Maintenance and Service Manual Page 11-21...
Page 120 TEST PROCEDURE 11 – Pin 5 See General Warnings on page 1-1. Pin 5 in the 16-pin connector provides a connection point for the solenoid lockout circuit from the onboard computer to the speed controller. Page 11-22 2009 Electric Precedent Maintenance and Service Manual...
Page 121 – Onboard computer for proper operation. See Test Procedure 19 – Onboard Computer Gray Wire on page 11-30. – Tow/Run switch for proper operation. See Test Procedure 6 – Tow/Run Switch on page 11-17. 2009 Electric Precedent Maintenance and Service Manual Page 11-23...
Page 122 – Continuity of the wires in the wire harness – Reverse buzzer for proper operation. See Test Procedure 24 – Reverse Buzzer on page 11-33. – Tow/Run switch for proper operation. See Tow/Run Switch on page 11-17. Page 11-24 2009 Electric Precedent Maintenance and Service Manual...
Page 123 (alligator clip) connected to the B– terminal of the speed controller. See previous CAUTION. 10. Place the Forward/Reverse switch in the NEUTRAL position. The multimeter should indicate zero volts DC at this time. 2009 Electric Precedent Maintenance and Service Manual Page 11-25...
Page 124 Using a multimeter set for 200 volts DC, insert the red (+) probe of the multimeter into pin 9 (gray wire) of the 16-pin connector. See following CAUTION. Using an alligator clip, connect the black (–) probe to the B– terminal of the speed controller (Figure 11-14, Page 11-27). Page 11-26 2009 Electric Precedent Maintenance and Service Manual...
Page 125 Using a multimeter set for 200 volts DC, insert the red (+) probe of the multimeter into pin 10 (tan wire) of the 16-pin connector. See following CAUTION. Using an alligator clip, connect the black (–) probe to the B– terminal of the speed controller (Figure 11-15, Page 11-28). 2009 Electric Precedent Maintenance and Service Manual Page 11-27...
Page 126 Place a jumper wire with an alligator clip between the B– terminal of the speed controller (use alligator clip for this connection) and pin 12 (blue/white wire) of the 16-pin connector (Figure 11-16, Page 11-29). See following CAUTION. Page 11-28 2009 Electric Precedent Maintenance and Service Manual...
Page 127 (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: 2009 Electric Precedent Maintenance and Service Manual Page 11-29...
Page 128 48-50 volts (full battery voltage). 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. Page 11-30 2009 Electric Precedent Maintenance and Service Manual...
Page 129 If the continuity is correct, replace the speed controller. 5.3. If reading is below 3.50 volts, check the continuity of the wires and plug and replace the speed controller if necessary. 2009 Electric Precedent Maintenance and Service Manual Page 11-31...
Page 130 Forward/Reverse Rocker Switch Test with the IQDM Handset Turn the key switch to the OFF position and place the Forward/Reverse switch in the NEUTRAL position. Connect the IQDM to the vehicle. Test FORWARD INPUT. Page 11-32 2009 Electric Precedent Maintenance and Service Manual...
Page 131 Computer Solenoid Lockout Circuit on page 11-15. See also Test Procedure 6 – Tow/Run Switch on page 11-17. 6.3. If the continuity readings are not correct, repair or replace the pink wire. 2009 Electric Precedent Maintenance and Service Manual Page 11-33...
Page 132 Install the wedgelock in the six-pin connector housing and reconnect the six-pin connector plug. Place the Tow/Run switch in the RUN position and the battery light should illuminate. If the light does not illuminate, replace the battery warning light assembly. Page 11-34 2009 Electric Precedent Maintenance and Service Manual...
Page 133: Communication Display Module (Cdm)
A problem may exist if persistent DVDT readings are obtained. • 4 – Indicates the last charge cycle was normal. 2009 Electric Precedent Maintenance and Service Manual Page 11-35...
Page 134: Using The Cdm To Retrieve Data From The Onboard Computer
• To view F4, press and hold the button on the CDM until “Func 4” appears in the display window. Release the button. The value for F4 will be displayed. NOTE: The values of all four functions can be recalled by pressing and releasing the CDM button. Page 11-36 2009 Electric Precedent Maintenance and Service Manual...
Page 135: Cdm Troubleshooting Guide
CDM Troubleshooting Guide 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 137: Section 12 - Excel System Troubleshooting
Program Menu. • Regenerative Braking: When motor braking is activated, the vehicle motor acts as a generator, slowing the vehicle as it creates energy that is used to charge the batteries. 2009 Electric Precedent Maintenance and Service Manual Page 12-1...
Page 138: Wiring Diagrams
W22 18_GRA Y W15 18_T AN W1 0 18_BLK_ W HT W17 18_BL U W32 18_ORG SW_6 W19 18_PUR_WH T RUN/TOW SWI TCH W28 16_PINK WD1035148-L Figure 12-1 Wiring Diagram – Excel System Page 12-2 2009 Electric Precedent Maintenance and Service Manual...
Page 139 SPEED SENSOR INPUT W05 18_RED SPEED SENSOR (+) W17 18_BL U RE VERS E MOTOR UNI T W19 18_PUR_WH T W28 16_PINK WD1035148-R Figure 12-2 Wiring Diagram – Excel System (Continued) 2009 Electric Precedent Maintenance and Service Manual Page 12-3...
Page 140 #16 GRAY #16 BROWN/WHITE #16 BROWN/WHITE NORMALLY OPEN MOM ENTARY, PUSH BU TTON FOR HORN USED WHEN THERE ARE TURN S IGNALS. WD1025104E5-L Figure 12-3 Precedent Electric Vehicle Accessory Wiring Diagram Page 12-4 2009 Electric Precedent Maintenance and Service Manual...
Page 141 SON IC #18 BLUE/WHITE DIODE WELD SO NIC WELD NOTE: SOME WIRING / COMPONENTS SHOWN ARE OPTIONAL ACCESSORIES. BRAKE LIGHT RELAY WD1025104E5-R Figure 12-4 Precedent Electric Vehicle Accessory Wiring Diagram (Continued) 2009 Electric Precedent Maintenance and Service Manual Page 12-5...
Page 142 #18 GREEN REVERS E BUZZER #18 BLACK PRO GRAMMER PLUG WARNING LIGHT NOTE: SOME WIRING / COMPONENTS S HOWN ARE OPTIONAL ACCESSORIES WD1025104E6 Figure 12-5 Precedent Electric Vehicle Instrument Panel Wiring Diagram Page 12-6 2009 Electric Precedent Maintenance and Service Manual...
Page 143: Troubleshooting
TROUBLESHOOTING THE VEHICLE WITH THE IQDM Club Car recommends the use of the IQDM handset for troubleshooting vehicles equipped with the Excel electrical system. Troubleshooting Guide 1 is to be used in conjunction with the IQDM handset. See IQ Display Module (IQDM) and IQDM-P Diagnostics: Excel System on page 14-1 for operating instructions.
Page 144 Repair and/or connect the 16-pin connector speed controller or broken wire to the speed controller Test Procedure 23 – Forward/Reverse Rocker Failed Forward/Reverse rocker switch Switch on page 12-32 TABLE CONTINUED ON NEXT PAGE Page 12-8 2009 Electric Precedent Maintenance and Service Manual...
Page 145 DRIVER OFF fault code symptom returns. Failure of the FET that controls the solenoid Replace the speed controller. See Speed coil Controller Removal on page 15-12. TABLE CONTINUED ON NEXT PAGE 2009 Electric Precedent Maintenance and Service Manual Page 12-9...
Page 146 Train operators to use the brake to hold the Diagnostic Menu – MOTOR STALL fault code Operator error vehicle on a hill, rather than holding the vehicle on a hill using the accelerator pedal Page 12-10 2009 Electric Precedent Maintenance and Service Manual...
Page 147: Troubleshooting Guide 2
Controller Removal on page 15-12. Motor – Motor connections Check for loose or disconnected wires Speed controller – Motor and power Check for loose or disconnected wires connections TABLE CONTINUED ON NEXT PAGE 2009 Electric Precedent Maintenance and Service Manual Page 12-11...
Page 148 Battery charger connections – loose wires at Check wire connections and tighten if charge batteries receptacle or batteries necessary. Refer to the appropriate battery charger Battery charger maintenance and service manual. Page 12-12 2009 Electric Precedent Maintenance and Service Manual...
Page 149: Test Procedures
16 – Pin 10 17 – Pin 12 18 – Onboard Computer Silicon-Controlled Rectifier (SCR) Circuit 19 – Onboard Computer Gray Wire 20 – Voltage at Charger Receptacle Red Wire Socket 2009 Electric Precedent Maintenance and Service Manual Page 12-13...
Page 150 2. BLACK probe to battery no. 4 (-). Figure 12-6 Battery Voltage Test – 4 x 12 Volt Battery Figure 12-7 Battery Voltage Test – 6 x 8 Volt Battery Configuration Configuration Page 12-14 2009 Electric Precedent Maintenance and Service Manual...
Page 151 Place red (+) probe of the multimeter on the positive (+) solenoid terminal. Place the black (–) probe on the other small solenoid terminal. A reading of 180 to 190 ohms should be obtained (Figure 12-8, Page 12-16). If not, replace the solenoid. 2009 Electric Precedent Maintenance and Service Manual Page 12-15...
Page 152 16-pin connector at the speed controller. Check terminal positions in six-pin connector at the sensor and the 16-pin connector. If all of the continuity readings are correct and the connectors are wired correctly, replace the speed controller. Page 12-16 2009 Electric Precedent Maintenance and Service Manual...
Page 153 TEST PROCEDURE 6 – Tow/Run Switch See General Warnings on page 1-1. Tow/Run Switch Test with the IQDM Handset With the Tow/Run switch in the RUN position, connect the IQDM to the vehicle. 2009 Electric Precedent Maintenance and Service Manual Page 12-17...
Page 154 Connect the tester leads to the positive (+) post of battery no.1 and negative (–) post of battery no. 4 (Figure 12-9, Page 12-19) or battery no. 6 (Figure 12-10, Page 12-19). Page 12-18 2009 Electric Precedent Maintenance and Service Manual...
Page 155 Testing battery voltage while the batteries are not under load will not always indicate the true condition of the batteries. For more information about the batteries, refer to Section 16 — Batteries . 2009 Electric Precedent Maintenance and Service Manual Page 12-19...
Page 156 4.3. With the key switch in the OFF position, the multimeter should indicate that continuity is not present. 4.4. With the key switch in the ON position, the multimeter should indicate that continuity is present. Page 12-20 2009 Electric Precedent Maintenance and Service Manual...
Page 157 When connecting the 16-pin connector to the controller, push plug into controller receptacle with enough force to lock plug into place. An audible click will be heard when plug is properly seated to the controller. 2009 Electric Precedent Maintenance and Service Manual Page 12-21...
Page 158 TEST PROCEDURE 11 – Pin 5 See General Warnings on page 1-1. Pin 5 in the 16-pin connector provides a connection point for the solenoid lockout circuit from the onboard computer to the speed controller. Page 12-22 2009 Electric Precedent Maintenance and Service Manual...
Page 159 – Onboard computer for proper operation. See Test Procedure 19 – Onboard Computer Gray Wire on page 12-30. – Tow/Run switch for proper operation. See Test Procedure 6 – Tow/Run Switch on page 12-17. 2009 Electric Precedent Maintenance and Service Manual Page 12-23...
Page 160 – Reverse buzzer for proper operation. See Test Procedure 24 – Reverse Buzzer on page 12-33. – Tow/Run switch for proper operation. See Test Procedure 6 – Tow/Run Switch on page 12-17. Page 12-24 2009 Electric Precedent Maintenance and Service Manual...
Page 161 (alligator clip) connected to the B– terminal of the speed controller. See previous CAUTION. 10. Place the Forward/Reverse switch in the NEUTRAL position. The multimeter should indicate zero volts DC at this time. 2009 Electric Precedent Maintenance and Service Manual Page 12-25...
Page 162 Using a multimeter set for 200 volts DC, insert the red (+) probe of the multimeter into pin 9 (gray wire) of the 16-pin connector. See following CAUTION. Using an alligator clip, connect the black (–) probe to the B– terminal of the speed controller (Figure 12-14, Page 12-27). Page 12-26 2009 Electric Precedent Maintenance and Service Manual...
Page 163 Using a multimeter set for 200 volts DC, insert the red (+) probe of the multimeter into pin 10 (tan wire) of the 16-pin connector. See following CAUTION. Using an alligator clip, connect the black (–) probe to the B– terminal of the speed controller (Figure 12-15, Page 12-28). 2009 Electric Precedent Maintenance and Service Manual Page 12-27...
Page 164 Place a jumper wire with an alligator clip between the B– terminal of the speed controller (use alligator clip for this connection) and pin 12 (blue/white wire) of the 16-pin connector (Figure 12-16, Page 12-29). See following CAUTION. Page 12-28 2009 Electric Precedent Maintenance and Service Manual...
Page 165 (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: 2009 Electric Precedent Maintenance and Service Manual Page 12-29...
Page 166 48-50 volts (full battery voltage). 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. Page 12-30 2009 Electric Precedent Maintenance and Service Manual...
Page 167 If the continuity is correct, replace the speed controller. 5.3. If reading is below 3.50 volts, check the continuity of the wires and plug and replace the speed controller if necessary. 2009 Electric Precedent Maintenance and Service Manual Page 12-31...
Page 168 Forward/Reverse Rocker Switch Test with the IQDM Handset Turn the key switch to the OFF position and place the Forward/Reverse switch in the NEUTRAL position. Connect the IQDM to the vehicle. Test FORWARD INPUT. Page 12-32 2009 Electric Precedent Maintenance and Service Manual...
Page 169 Computer Solenoid Lockout Circuit on page 12-15. See also Test Procedure 6 – Tow/Run Switch on page 12-17. 6.3. If the continuity readings are not correct, repair or replace the pink wire. 2009 Electric Precedent Maintenance and Service Manual Page 12-33...
Page 170 Install the wedgelock in the six-pin connector housing and reconnect the six-pin connector plug. Place the Tow/Run switch in the RUN position and the battery light should illuminate. If the light does not illuminate, replace the battery warning light assembly. Page 12-34 2009 Electric Precedent Maintenance and Service Manual...
Page 171: Communication Display Module (Cdm)
• 2 – Indicates a back-up charge program was employed by the OBC to complete the charge cycle. A DVDT charge may be displayed the first few times a new set of batteries is charged, and the first time a set of batteries is 2009 Electric Precedent Maintenance and Service Manual Page 12-35...
Page 172: Using The Cdm To Retrieve Data From The Onboard Computer
• To view F4, press and hold the button on the CDM until “Func 4” appears in the display window. Release the button. The value for F4 will be displayed. NOTE: The values of all four functions can be recalled by pressing and releasing the CDM button. Page 12-36 2009 Electric Precedent Maintenance and Service Manual...
Page 173: Cdm Troubleshooting Guide
CDM Troubleshooting Guide 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 175: Section 13 - Iq Display Module (Iqdm) And Iqdm-Pdiagnostics: Iq System
Immediately after the handset is connected to the vehicle, it begins loading the vehicle speed controller information. After a few seconds, the screen displays the following menu items: • Program (IQDM-P only) • Monitor • Faults 2009 Electric Precedent Maintenance and Service Manual Page 13-1...
Page 176: Menu Navigation
NOTE: When going to a bookmarked display screen, be sure to rapidly press and release the button. If the button is pressed and held for too long, the bookmark will be overridden with the current screen. Page 13-2 2009 Electric Precedent Maintenance and Service Manual...
Page 177: Program (Iqdm-P Only)
The program menu allows the user to view and change custom speed controller settings. See Program Menu on page 20-2. MONITOR The monitor menu displays values for certain parameters to facilitate speed controller troubleshooting. See Monitor Menu on page 13-4. 2009 Electric Precedent Maintenance and Service Manual Page 13-3...
Page 178: Faults
Indicates the position of the accelerator pedal from 0% (pedal not pressed) to 95 - 100% (pedal fully pressed). This item can be monitored when the key switch is in the ON or OFF position. Page 13-4 2009 Electric Precedent Maintenance and Service Manual...
Page 179: Batt Voltage
When the accelerator pedal is unpressed, the handset should indicate that the limit switch is off. When the accelerator pedal is pressed and the key switch is in the ON position, the display should indicate that the limit switch is on. 2009 Electric Precedent Maintenance and Service Manual Page 13-5...
Page 180: Forward Input
“private speed mode”. In the event that “private speed mode” is locked out, the controller must be removed and shipped to Club Car before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 20-3.
Page 181: Faults Menu
The vehicle speed controller should be checked for fault codes before any service is performed. 2009 Electric Precedent Maintenance and Service Manual Page 13-7...
Page 182 A, B, C PROC/WIRING OVERVOLTAGE A, B, G LOW BATTERY THERMAL CUTBACK MOTOR STALL MAIN DROPOUT A, C OPEN ARMATURE MAX PASSWORD TRIES (no action taken) INCORRECT PASSWORD (no action taken) Page 13-8 2009 Electric Precedent Maintenance and Service Manual...
Page 183: Hw Failsafe
1. the run/tow switch had been placed in the tow position, 2. the DC plug of the charger had been plugged into the vehicle, 3. the battery set had been disconnected or 4. 2009 Electric Precedent Maintenance and Service Manual Page 13-9...
Page 184: Throttle Fault 1
8 seconds, the controller detects a high speed walkaway fault. MAIN COIL FAULT If the speed controller determines that the solenoid is not closing as a result of a solenoid coil failure, a main coil fault is detected. Page 13-10 2009 Electric Precedent Maintenance and Service Manual...
Page 185: Field Missing
MAIN DROPOUT If the controller detects that the solenoid contacts have opened while the vehicle is in operation, a main dropout fault is detected. 2009 Electric Precedent Maintenance and Service Manual Page 13-11...
Page 186: Open Armature
The max password tries fault is declared when the incorrect password fault has been declared several times. In the event that the max password tries fault is indicated, the speed controller must be removed and shipped to Club Car before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 20-3. See also Password Tries (IQDM-P only) on page 13-6.
Page 187: Functions Menu
IQ System vehicle or group of IQ System vehicles. See Speed Controller Cloning – Transferring Settings from the Handset to the Vehicle on page 13-14. 2009 Electric Precedent Maintenance and Service Manual Page 13-13...
Page 188: Write Settings To Controller
4.4. Align the keyed portion of the plug with the IQDM port and connect the plug to the port (Figure 13-1, Page 13-2). Scroll to the functions menu and select. Select settings. Page 13-14 2009 Electric Precedent Maintenance and Service Manual...
Page 189: Reset All Settings
During an active session when the settings need to be returned to the original values (the values that were active at the beginning of the session), scroll to the functions menu and select. Select settings. Select reset all settings. Press + on the change value button to confirm the operation. 2009 Electric Precedent Maintenance and Service Manual Page 13-15...
Page 190: Information
Displays the model number of the speed controller. SERIAL NUMBER Displays the serial number of the speed controller. MFG DATE Displays the date the speed controller was manufactured. SOFTWARE VERSION Displays the speed controller software version. Page 13-16 2009 Electric Precedent Maintenance and Service Manual...
Page 191: Programmer Setup
This menu selection displays information pertaining to the handset. The information provided in this menu selection includes model number, serial number, the date the handset was manufactured, the handset software version, etc. 2009 Electric Precedent Maintenance and Service Manual Page 13-17...
Page 192: Iqdm And Iqdm-P Handset Troubleshooting
Test Procedure 2 – Handset Cord Adaptor on Intermittent handset cord adaptor failure page 13-19 Loose vehicle wire harness connections Test Procedure 3 – IQDM Ports on page 13-20 TABLE CONTINUED ON NEXT PAGE Page 13-18 2009 Electric Precedent Maintenance and Service Manual...
Page 193: Test Procedures
Using a multimeter set for 200 ohms, place the red (+) probe into one of the terminals on the end of the adapter with the square plug. Place the black (–) probe on each of the pins, one at a time, on the other plug of the adaptor. 2009 Electric Precedent Maintenance and Service Manual Page 13-19...
Page 194 Warnings on page 1-1. 4.2. Remove electronics module cover. See Electronics Module Cover on page 15-5.. 4.3. Connect IQDM to controller 4.3.1. Disconnect the square four-pin connector (3) from the speed controller. Page 13-20 2009 Electric Precedent Maintenance and Service Manual...
Page 195 See Test Procedure 2 – Handset Cord Adaptor on page 13-19. See Section 11 — IQ System Troubleshooting . 4.4. Replace electronics module cover. See Electronics Module Cover Installation on page 15-5. Figure 13-8 IQDM Connector On Speed Controller 2009 Electric Precedent Maintenance and Service Manual Page 13-21...
Page 197: Section 14 - Iq Display Module (Iqdm) And Iqdm-Pdiagnostics: Excel System
Align the keyed portion of the plug with the IQDM port and connect the plug to the port. 1. IQDM Series 1 2. IQDM Series 2 1315 Figure 14-1 IQDM Port Under Instrument Panel Figure 14-2 IQDM Versions 2009 Electric Precedent Maintenance and Service Manual Page 14-1...
Page 198: Introductory Display
NOTE: When going to a bookmarked display screen, be sure to rapidly press and release the button. If the button is pressed and held for too long, the bookmark will be overridden with the current screen. Page 14-2 2009 Electric Precedent Maintenance and Service Manual...
Page 199: Program (Iqdm-P Only)
The program menu allows the user to view and change custom speed controller settings. See Program Menu on page 21-2. MONITOR The monitor menu displays values for certain parameters to facilitate speed controller troubleshooting. See Monitor Menu on page 14-4. 2009 Electric Precedent Maintenance and Service Manual Page 14-3...
Page 200: Faults
Failure to heed this warning could result in severe personal injury or death. The following parameters can be monitored in real time with the handset from the monitor menu: Page 14-4 2009 Electric Precedent Maintenance and Service Manual...
Page 201: Speed
Displays motor field PWM (pulse width modulation). The range of pulse width modulation is 0% to 100%. When the vehicle is in operation, the pulse width modulation will fluctuate in response to the terrain and throttle input. 2009 Electric Precedent Maintenance and Service Manual Page 14-5...
Page 202: Brake Volts In
CHARGER INHIBIT Displays charger connection. When the controller energizes the solenoid coil, the handset indicates ON. When the controller de-energizes the solenoid coil, the handset indicates OFF. Page 14-6 2009 Electric Precedent Maintenance and Service Manual...
Page 203: Main Cont Driver
“private speed mode”. In the event that “private speed mode” is locked out, the controller must be removed and shipped to Club Car before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 21-4.
Page 204: Faults Menu
The vehicle speed controller should be checked for fault codes before any service is performed. Page 14-8 2009 Electric Precedent Maintenance and Service Manual...
Page 205 MAX PASSWORD TRIES (no action taken) INCORRECT PASSWORD (no action taken) BLD OVERCURRENT Not Applicable At This Time MAIN DRIVER OVERCURRENT A, B CURRENT SENSE FAULT A, B M– SHORTED A, B, C 2009 Electric Precedent Maintenance and Service Manual Page 14-9...
Page 206: Hw Failsafe
FET’s or circuitry, a hardware failsafe fault is detected. THROTTLE FAULT If the throttle position sensor voltage is less than 0.20 volts or greater than 4.80 volts, the controller detects a throttle fault. Page 14-10 2009 Electric Precedent Maintenance and Service Manual...
Page 207: Speed Sensor
OVERVOLTAGE If the speed controller detects that the battery voltage is too high (68.4 to 75.6 volts DC), the overvoltage fault is detected. 2009 Electric Precedent Maintenance and Service Manual Page 14-11...
Page 208: Low Battery Voltage
Page 14-12 2009 Electric Precedent Maintenance and Service Manual...
Page 209: Clearing Fault History
Excel System vehicle or group of Excel System vehicles. See Speed Controller Cloning – Transferring Settings from the Handset to the Vehicle on page 14-14. 2009 Electric Precedent Maintenance and Service Manual Page 14-13...
Page 210: Write Settings To Controller
4.4. Align the keyed portion of the plug with the IQDM port and connect the plug to the port (Figure 14-1, Page 14-1). Scroll to the functions menu and select. Select settings. Page 14-14 2009 Electric Precedent Maintenance and Service Manual...
Page 211: Reset All Settings
During an active session when the settings need to be returned to the original values (the values that were active at the beginning of the session), scroll to the functions menu and select. Select settings. Select reset all settings. Press + on the change value button to confirm the operation. 2009 Electric Precedent Maintenance and Service Manual Page 14-15...
Page 212: Information
Displays the model number of the speed controller. SERIAL NUMBER Displays the serial number of the speed controller. MFG DATE Displays the date the speed controller was manufactured. SOFTWARE VERSION Displays the speed controller software version. Page 14-16 2009 Electric Precedent Maintenance and Service Manual...
Page 213: Programmer Setup
This menu selection displays information pertaining to the handset. The information provided in this menu selection includes model number, serial number, the date the handset was manufactured, the handset software version, etc. 2009 Electric Precedent Maintenance and Service Manual Page 14-17...
Page 214: Iqdm And Iqdm-P Handset Troubleshooting
Test Procedure 2 – Handset Cord Adaptor on Intermittent handset cord adaptor failure page 14-19 Loose vehicle wire harness connections Test Procedure 3 – IQDM Ports on page 14-20 TABLE CONTINUED ON NEXT PAGE Page 14-18 2009 Electric Precedent Maintenance and Service Manual...
Page 215: Test Procedures
Using a multimeter set for 200 ohms, place the red (+) probe into one of the terminals on the end of the adapter with the square plug. Place the black (–) probe on each of the pins, one at a time, on the other plug of the adaptor. 2009 Electric Precedent Maintenance and Service Manual Page 14-19...
Page 216 Warnings on page 1-1. 4.2. Remove electronics module cover. See Electronics Module Cover on page 15-5. 4.3. Connect IQDM to controller. 4.3.1. Disconnect the square four-pin connector (3) from the speed controller. Page 14-20 2009 Electric Precedent Maintenance and Service Manual...
Page 217 See Test Procedure 2 – Handset Cord Adaptor on page 14-19. See Section 12 — Excel System Troubleshooting . 4.4. Replace electronics module cover. See Electronics Module Cover on page 15-5. Figure 14-9 IQDM Connector On Speed Controller 2009 Electric Precedent Maintenance and Service Manual Page 14-21...
Page 219: Section 15 - Electrical Components
3.2. Position the instrument panel (2) on the dash assembly. Make sure tabs on upper edge properly engage with the corresponding slots on the dash assembly. Ensure that there are no wires exposed or pinched during positioning. 2009 Electric Precedent Maintenance and Service Manual Page 15-1...
Page 220: Battery Warning Light
Remove instrument panel. See Key Switch Removal on page 15-1. Disconnect the wires at the warning light. Press the two retaining tabs (11) and remove the light from the center dash (Figure 15-3, Page 15-3). Page 15-2 2009 Electric Precedent Maintenance and Service Manual...
Page 221: Battery Warning Light Installation
Remove two screws (2) that hold Forward/Reverse rocker switch housing (1) to the vehicle (Figure 15-4, Page 15-4). Remove the three wires from the rocker switch. Press in on the locking tabs on each side of switch (3), and push switch out of housing. 2009 Electric Precedent Maintenance and Service Manual Page 15-3...
Page 222: Forward/Reverse Rocker Switch Installation
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 15-4 2009 Electric Precedent Maintenance and Service Manual...
Page 223: Electronics Module Cover
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. 2009 Electric Precedent Maintenance and Service Manual Page 15-5...
Page 224: Tow/Run Switch
Installation is reverse of removal. Make sure flat on switch is aligned with flat part of D-shaped hole in electronics module (Figure 15-6, Page 15-7). Tighten Tow/Run switch boot/hex nut (1) to 16 in-lb (1.8 N·m). Connect the wires to the switch. Page 15-6 2009 Electric Precedent Maintenance and Service Manual...
Page 225: Throttle Position Sensor
The throttle position sensor itself is not intended to be replaced. If sensor is determined to need replacing through test procedures listed above, the accelerator pedal assembly must be replaced. See Accelerator Pedal Removal on page 5-3. 2009 Electric Precedent Maintenance and Service Manual Page 15-7...
Page 226: Reverse Buzzer
110 in-lb (12.4 N·m) and coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion. (Viewed from underside of instrument panel) A. Pink B. Orange/White Figure 15-7 Reverse Buzzer Page 15-8 2009 Electric Precedent Maintenance and Service Manual...
Page 227: Electronics Module
Set electronics module in place and secure with bolt (11) (Figure 15-8, Page 15-11). Tighten bolt to 40 in-lb (4.5 N·m). Install the batteries and battery cables in their original locations. See Battery Replacement on page 16-15. 2009 Electric Precedent Maintenance and Service Manual Page 15-9...
Page 228 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 15-10 2009 Electric Precedent Maintenance and Service Manual...
Page 229 ELECTRICAL COMPONENTS Electronics Module Figure 15-8 Electronics Module Removal 2009 Electric Precedent Maintenance and Service Manual Page 15-11...
Page 230: Speed Controller
Inspect the vehicle for proper operation. WARNING • Make sure that the vehicle operates in the forward direction when the Forward/Reverse switch is in the FORWARD position. WARNING CONTINUED ON NEXT PAGE Page 15-12 2009 Electric Precedent Maintenance and Service Manual...
Page 231: Solenoid
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. 2009 Electric Precedent Maintenance and Service Manual Page 15-13...
Page 232: Onboard Computer (Obc)
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 15-14 2009 Electric Precedent Maintenance and Service Manual...
Page 233: Charger Receptacle
Warnings on page 1-1. Remove kick plate. See Kick Plate and Charger Receptacle Bezel on page 4-8. Remove the 10-gauge red wire from the positive post of battery no. 1 (Figure 15-9, Page 15-15). 2009 Electric Precedent Maintenance and Service Manual Page 15-15...
Page 234: Charger Receptacle Installation
Tighten screws to 66 in-lb (7.5 N·m). While it is possible to add washers with the headlight/bumper assembly mounted to the vehicle, these adjustments may be easier if the headlight/front bumper assembly is unbolted first (Figure 15-10, Page 15-17). Page 15-16 2009 Electric Precedent Maintenance and Service Manual...
Page 235 ELECTRICAL COMPONENTS Headlight Adjustment Figure 15-10 Headlight Aiming 2009 Electric Precedent Maintenance and Service Manual Page 15-17...
Page 236: Ferrite Beads - Ce Mark Vehicles
6. This wire tie goes around 4 wires (6 Ga. White, 6 Ga. Green, 10 Ga. Orange, 10 Ga. Blue) between the bead (item 1) and controller. 1314 Figure 15-11 Ferrite Bead Placement For Precedent Vehicles Page 15-18 2009 Electric Precedent Maintenance and Service Manual...
Page 237: Section 16 - Batteries
The 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. 2009 Electric Precedent Maintenance and Service Manual Page 16-1...
Page 238: Battery Troubleshooting Chart
If discharge time is 60 minutes or If discharge time is less than 60 minutes, replace all batteries below 6.7 volts. more, problem is not with the batteries. Figure 16-1 Battery Troubleshooting Chart Page 16-2 2009 Electric Precedent Maintenance and Service Manual...
Page 239: Battery Testing - 12 Volt
Be sure batteries have sufficient electrolyte to cover plates by approximately 1/2 inch (13 mm) and are fully charged prior to beginning test. If water must be added, recharge the batteries before performing the hydrometer test. See following CAUTION. 2009 Electric Precedent Maintenance and Service Manual Page 16-3...
Page 240 For each 10 °F (5.6 °C) above 80 °F (26.7 °C), add 0.004 to the reading. For each 10 °F (5.6 °C) below 80 °F (26.7 °C), subtract 0.004 from the reading. 1.250 1.280 View at eye level. Figure 16-2 Hydrometer Test Page 16-4 2009 Electric Precedent Maintenance and Service Manual...
Page 241 Cell Dead – .000 – 0 = – 0 does – 0 = – 0 = – 0 = (26.7 °C) Replace Battery 1.240 = 1.245 not rise 1.235 1.250 1.240 2009 Electric Precedent Maintenance and Service Manual Page 16-5...
Page 242: Discharge Test
(Viewed from driver side of vehicle) 1. RED probe to battery no. 1 (+). 2. BLACK probe to battery no. 4 (-). Figure 16-3 Battery Discharge Test – 4 x 12 Volt Battery Configuration Page 16-6 2009 Electric Precedent Maintenance and Service Manual...
Page 243 70-74 °F 120-129 °F 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) 2009 Electric Precedent Maintenance and Service Manual Page 16-7...
Page 244: Battery Troubleshooting Examples
Battery no. 2 should be replaced with a battery that has the same age and usage as the other batteries in the set. Page 16-8 2009 Electric Precedent Maintenance and Service Manual...
Page 245: Battery Testing - 8 Volt
Be sure batteries have sufficient electrolyte to cover plates by approximately 1/2 inch (13 mm) and are fully charged prior to beginning test. If water must be added, recharge the batteries before performing the hydrometer test. See following CAUTION. 2009 Electric Precedent Maintenance and Service Manual Page 16-9...
Page 246 For each 10 °F (5.6 °C) above 80 °F (26.7 °C), add 0.004 to the reading. For each 10 °F (5.6 °C) below 80 °F (26.7 °C), subtract 0.004 from the reading. 1.250 1.280 View at eye level. Figure 16-4 Hydrometer Test Page 16-10 2009 Electric Precedent Maintenance and Service Manual...
Page 247 = 1.188 = 1.178 Recharge and Recheck 1.240 – 0 = 1.245 – 0 Float does no.3 Cell Dead – 80 °F (26.7 °C) 0.000 1.240 = 1.245 not rise Replace Battery 2009 Electric Precedent Maintenance and Service Manual Page 16-11...
Page 248: Discharge Test
(Viewed from driver side of vehicle) 1. RED probe to battery no. 1 (+). 2. BLACK probe to battery no. 6 (-). Figure 16-5 Battery Discharge Test – 6 x 8 Volt Battery Configuration Page 16-12 2009 Electric Precedent Maintenance and Service Manual...
Page 249 70-74 °F 120-129 °F 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) 2009 Electric Precedent Maintenance and Service Manual Page 16-13...
Page 250: Battery Troubleshooting Examples
Battery no. 2 should be replaced with a battery that has the same age and usage as the other batteries in the set. Page 16-14 2009 Electric Precedent Maintenance and Service Manual...
Page 251: Battery Replacement
Battery Terminal Protector Spray (CCI P/N 1014305) to minimize future corrosion. Give the batteries a full charge prior to operation. This ensures all the batteries are fully charged and the cells are equalized prior to use. 2009 Electric Precedent Maintenance and Service Manual Page 16-15...
Page 252: Battery Care
(do not leave discharged overnight). Water the batteries monthly or according to the watering interval. See Establishing the Watering Interval for New Vehicles on page 16-17. See Watering Batteries with the SPWS on page 16-23. Page 16-16 2009 Electric Precedent Maintenance and Service Manual...
Page 253: Battery Care - Vehicles Without The Single-Point Watering System
See step 8 of Battery Replacement on page 16-15. The terminal connections should be clean and tight, and any worn insulation or frayed wires should be replaced. Tighten battery terminals to 110 in-lb (12.4 N·m). See following WARNING. 2009 Electric Precedent Maintenance and Service Manual Page 16-17...
Page 254: Self-Discharge
The electrolyte level should be checked weekly to be sure electrolyte is at its proper level (Figure 16-8, Page 16-18). Never allow the electrolyte level to fall below the tops of the plates because this will cause the exposed part of the plate Page 16-18 2009 Electric Precedent Maintenance and Service Manual...
Page 255: Mineral Content
The batteries should be charged every day they are used. However, the batteries should not be charged if they have not been used. 2009 Electric Precedent Maintenance and Service Manual Page 16-19...
Page 256: Charging Batteries
When inserting the DC plug, align the raised guide on the plug with the guide slot in the receptacle and push straight in slowly. Club Car battery chargers interact with the vehicle’s onboard computer. The computer records the amount of energy consumed during vehicle use. While the charger is plugged in, the vehicle’s control circuit is locked out, preventing operation of the vehicle as well as the possibility of consequent damage to the charger and the vehicle.
Page 257: Plug And Receptacle
Batteries should be put on charge even if they have been used for only a short period (10 minutes). The charger is automatic and will turn off when batteries are fully charged. If the charger does not seem to be operating properly, or if the batteries seem weak, contact your local Club Car distributor/dealer. PLUG AND RECEPTACLE The charger cord, plug, and receptacle are wear items and should be inspected daily.
Page 258: Early Excessive Discharging
SINGLE POINT WATERING SYSTEM (SPWS) CAUTION • Water the batteries only AFTER charging. • Use only the equipment provided in the Club Car SPWS Refill Kit (CCI P/N 102958001) to water batteries with the SPWS. Page 16-22 2009 Electric Precedent Maintenance and Service Manual...
Page 259: Initial Maintenance Of The Spws
(6). See following NOTE. NOTE: The water flow rate must be at least two gallons-per-minute for the SPWS to function properly. This step also eliminates any trapped air from the water hose. 2009 Electric Precedent Maintenance and Service Manual Page 16-23...
Page 260 Place the battery fill coupling into the space between the battery bucket and the car body. Leaving the fill coupling on top of the battery bank or tucked between the batteries and the battery bucket can result in coupling damage. Turn the water faucet off when finished filling the vehicle(s). Page 16-24 2009 Electric Precedent Maintenance and Service Manual...
Page 261: Battery Storage
ON, during off-season storage. The storage charge feature will automatically charge the batteries as needed throughout the storage period. CHARGING A BATTERY PACK THAT HAS LOW VOLTAGE See the appropriate battery charger maintenance and service manual. 2009 Electric Precedent Maintenance and Service Manual Page 16-25...
Page 263: Section 17 - Battery Charger
SECTION 17 — BATTERY CHARGER Refer to the appropriate battery charger maintenance and service manual. 2009 Electric Precedent Maintenance and Service Manual Page 17-1...
Page 265: Section 18 - Motor (Model Ej4-4001 And Ej8-4001A)
The vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. The shunt-wound motor is designed for use in IQ and Excel System vehicles only. Club Car recommends that motors requiring major repair be sent to a qualified motor repair shop; however, there are many relatively simple tasks that can be performed by a technician with general knowledge and experience in electric motor repair.
Page 266 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. Page 18-2 2009 Electric Precedent Maintenance and Service Manual...
Page 267: Motor
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 18-3, Page 18-4). 2009 Electric Precedent Maintenance and Service Manual Page 18-3...
Page 268: Motor Disassembly
Before beginning disassembly, place match marks on the motor end cap and motor frame. Remove speed sensor and magnet. 2.1. Remove the two screws (25) that secure the speed sensor (10) to the end cap (11) (Figure 18-15, Page 18-11). Page 18-4 2009 Electric Precedent Maintenance and Service Manual...
Page 269 NOTE: Replacement of the end cap bearing is recommended if the armature is removed. 2009 Electric Precedent Maintenance and Service Manual Page 18-5...
Page 270 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 18-10. Figure 18-8 Armature Removal Figure 18-9 A1 and A2 Terminals Page 18-6 2009 Electric Precedent Maintenance and Service Manual...
Page 271: Motor Component Testing And Inspection
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. See following CAUTION and NOTE. 2009 Electric Precedent Maintenance and Service Manual Page 18-7...
Page 272 With a multimeter set to 200 ohms, place one probe on the commutator (1) and the other on the armature core (2). The multimeter should indicate no continuity (Figure 18-12, Page 18-8). If the reading is incorrect, replace the armature. Figure 18-12 Armature Test Page 18-8 2009 Electric Precedent Maintenance and Service Manual...
Page 273: Motor Frame And Field Windings Inspection
Remove the terminal insulators by performing steps 1 through 12 of Motor Disassembly on page 18-4. Inspect the insulators (4 and 6) for cracks or other damage (Figure 18-15, Page 18-11). Replace insulators as required. 2009 Electric Precedent Maintenance and Service Manual Page 18-9...
Page 274 Figure 18-13 Brush Spring Tension Test Figure 18-14 Bearing Inspection Speed Sensor Magnet Inspection Inspect the speed sensor magnet (24) for rust, wear, and cracks (Figure 18-15, Page 18-11). Replace the magnet if necessary. Page 18-10 2009 Electric Precedent Maintenance and Service Manual...
Page 275 MOTOR (MODEL EJ4-4001 AND EJ8-4001A) Motor Component Testing and Inspection Items 19, 20, 21, and 22: Used only on EJ4–4001 motor Figure 18-15 Motor 2009 Electric Precedent Maintenance and Service Manual Page 18-11...
Page 276: Reconditioning The Motor
2.5. One at a time, push the brushes back until they are completely retracted into their mounting slots and the spring pressure holds them in the retracted position as shown (Figure 18-17, Page 18-13). Page 18-12 2009 Electric Precedent Maintenance and Service Manual...
Page 277 Install the speed sensor (10) with screws (25). Tighten to 25 in-lb (2.8 N·m). Make sure the armature turns freely. If it does not turn freely, disassemble the motor to find the problem. 2009 Electric Precedent Maintenance and Service Manual Page 18-13...
Page 278: Motor Installation
4.1. Slide the motor coupling onto the transaxle input shaft. See following NOTE. NOTE: The coupling will push any excess grease on the input shaft along the shaft toward the transaxle. Page 18-14 2009 Electric Precedent Maintenance and Service Manual...
Page 279 For 5/16 inch (8mm) diameter studs, tighten the nuts to 100 in-lb (11 N·m). For 1/4 inch (6.3mm) diameter studs, tighten the nuts to 45 in-lb (5.0 N·m). 2009 Electric Precedent Maintenance and Service Manual Page 18-15...
Page 280 • Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. 1313 Figure 18-24 EJ4–4001 Motor Mounting Bolts and Figure 18-25 EJ8–4001A Motor Mounting Bolts and Tightening Sequence Tightening Sequence Page 18-16 2009 Electric Precedent Maintenance and Service Manual...
Page 281: Section 19 - Transaxle (Type G)
If necessary, remove the axle oil seal and adapter ring. 6.1. Use a bearing puller (CCI P/N 1016417) to remove the axle seal and adapter ring from the axle tube (Figure 19-2, Page 19-2). See following CAUTION and NOTE. 2009 Electric Precedent Maintenance and Service Manual Page 19-1...
Page 282 Figure 19-1 Remove Internal Retaining Ring Figure 19-2 Axle Seal and Adapter Ring Removal A. Adapter Ring Lip Figure 19-3 Axle Seal and Adapter Ring Figure 19-4 Axle Seal and Adapter Ring Installation Page 19-2 2009 Electric Precedent Maintenance and Service Manual...
Page 283 TRANSAXLE (TYPE G) Axle Bearing and Shaft Figure 19-5 Transaxle – Type G 2009 Electric Precedent Maintenance and Service Manual Page 19-3...
Page 284: 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 19-5, Page 19-3). Page 19-4 2009 Electric Precedent Maintenance and Service Manual...
Page 285: Transaxle
10. Remove the three motor mounting bolts (1) (Figure 19-11, Page 19-7) and the motor positioning bolt (EJ4–4001 and 5BC59JBS6390 motors only) (Figure 19-12, Page 19-7), securing the motor to the transaxle. See following CAUTION. 2009 Electric Precedent Maintenance and Service Manual Page 19-5...
Page 286 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 on page 6-11. Page 19-6 2009 Electric Precedent Maintenance and Service Manual...
Page 287 TRANSAXLE (TYPE G) Transaxle 1. Precedent 2. Villager 4 Figure 19-10 Leaf Springs Figure 19-11 Motor Mounting Bolts Figure 19-12 Motor Positioning Bolt – EJ4–4001 and 5BC59JBS6390 Motors Only 2009 Electric Precedent Maintenance and Service Manual Page 19-7...
Page 288: Transaxle Disassembly, Inspection, And Assembly
19-5, Page 19-3). See also Figure 19-13, Page 19-8. Press the bearing (18) off the intermediate gear assembly (Figure 19-5, Page 19-3). 1. Press Ram 2. Arbor Figure 19-13 Intermediate Gear Assembly Page 19-8 2009 Electric Precedent Maintenance and Service Manual...
Page 289 • Do not reuse bearings after removing them. Replace bearings with new ones. Inspect parts for wear or damage. Any worn or damaged parts should be replaced. See following NOTE. NOTE: Damaged or worn gears should be replaced as sets. 2009 Electric Precedent Maintenance and Service Manual Page 19-9...
Page 290: Transaxle Assembly
11.3. Place a 1/4 to 3/8-inch (6 to 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 19-10 2009 Electric Precedent Maintenance and Service Manual...
Page 291: Transaxle Installation
110 in-lb (12.4 N·m) and coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion. 14. Inspect the vehicle to check for proper operation. See following WARNING. 2009 Electric Precedent Maintenance and Service Manual Page 19-11...
Page 292 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 19-12 2009 Electric Precedent Maintenance and Service Manual...
Page 293: Section 20 - Iq Display Module Programmer (Iqdm-P): Iq System
Remove the dust cap from the IQDM jack. Align the keyed portion of the plug with the IQDM jack and connect the plug to the jack. Figure 20-1 IQDM Port Under Instrument Panel 2009 Electric Precedent Maintenance and Service Manual Page 20-1...
Page 294: Program Menu
Use the change value button to change the values of the selected item as necessary. The following parameters can be programmed with the handset from the program menu: Figure 20-2 Access Program Menu Figure 20-3 Change Speed Setting Page 20-2 2009 Electric Precedent Maintenance and Service Manual...
Page 295: Speed Setting
ANSI Z130.1 – American National Standard for Golf Cars – Safety and Performance Specifications because it is capable of speeds in excess of 15 mph (24.1 km/h). For more information on this feature, contact your local Club Car distributor or dealer. 2009 Electric Precedent Maintenance and Service Manual Page 20-3...
Page 296: Slow Pedal Up
(18.4, 20.0, 21.3 and 22.6 km/h, respectively). The default SPEED 2 speed setting is 13.2 mph (21.3 km/h). The top speed of the vehicle can be set between 11.2 to 14.8 mph in 0.2 mph (18.1 to 23.9 km/h in 0.3 km/h) increments. (The IQDM displays mph as “%”). Page 20-4 2009 Electric Precedent Maintenance and Service Manual...
Page 297: Section 21 - Iq Display Module Programmer (Iqdm-P): Excel System
Align the keyed portion of the plug with the IQDM jack and connect the plug to the jack. 1. IQDM–P Series 1 2. IQDM–P Series 2 1315 Figure 21-1 IQDM Port Under Instrument Panel Figure 21-2 IQDM–P Versions 2009 Electric Precedent Maintenance and Service Manual Page 21-1...
Page 298: Program Menu
Use the change value button to change the values of the selected item as necessary. The following parameters can be programmed with the handset from the program menu: Figure 21-3 Access Program Menu Figure 21-4 Change Speed Setting Page 21-2 2009 Electric Precedent Maintenance and Service Manual...
Page 299: Speed Setting
For example, if the speed setting is set for a value of 2 (11.4 mph (18.3 km/h)), and the speed calibration is set for 5, the total top speed of the vehicle should be approximately 10.9 mph (17.5 km/h). 2009 Electric Precedent Maintenance and Service Manual Page 21-3...
Page 300: S3 Fwd Speed
15 mph (24.1 km/h). For more information on this feature, contact your local Club Car distributor or dealer. VEHICLE S/N Six digit number programmed by vehicle manufacturer. VEHICLE DECAL Decal number ranging from 0 - 999 and programmed by vehicle manufacturer. Page 21-4 2009 Electric Precedent Maintenance and Service Manual...
Page 301 ..... 19-4 function codes........11-35, 12-35 bearing, motor retrieving data from ....... 11-36, 12-36 see motor, bearing........... 18-10 troubleshooting ........11-37, 12-37 body, front ............4-3, 4-9 connector, 16-pin 2009 Electric Precedent Maintenance and Service Manual Page i-1...
Page 302 Reset All Settings......... 13-15 System Faults..........13-7 inspection Test Procedures........... 13-19 front wheel free play .......... 7-17 Troubleshooting ........... 13-18 motor Write Settings to Controller ......13-14 armature ground test ........18-8 Page i-2 2009 Electric Precedent Maintenance and Service Manual...
Page 303 ..........11-1, 12-1, 18-1 installation ............7-8 armature removal .............. 7-4 ground test ............ 18-8 rear beauty panel inspection............18-7 installation ..........4-11, 4-15 assembly ............18-12 removal ............ 4-11, 4-15 bearing rear body 2009 Electric Precedent Maintenance and Service Manual Page i-3...
Page 304 11-21, 12-21 battery pack voltage (under load) .....11-18, installation ............15-12 12-18 removal ............15-12 battery warning light ......11-34, 12-34 steering charger receptacle......... 11-30, 12-30 rack and pinion Page i-4 2009 Electric Precedent Maintenance and Service Manual...
Page 305 ............. 19-4 removal ............19-1 removal ............19-5 troubleshooting..........11-2, 12-2 battery troubleshooting examples ....16-8, 16-14 communication display module (CDM)... 11- 37, 12-37 IQDM and IQDM-P handset ....13-18, 14-18 2009 Electric Precedent Maintenance and Service Manual Page i-5...
Page 309 1. Ease of Understanding 2. Ease of Finding Information 3. Clarity of Illustrations Comments/Suggestions Please fax a copy of this page to (706) 228-2662. T hank Y ou! Club Car Technical Publication Department 2009 Electric Precedent Maintenance and Service Manual...

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