User Manuals: Club Car Electric Precedent 2008 Cart

User Manuals: Club Car Electric Precedent 2008 Cart

Manuals and User Guides for Club Car Electric Precedent 2008 Cart. We have 1 Club Car Electric Precedent 2008 Cart manual available for free PDF download: Maintenance And Service Manual

Club Car Electric Precedent 2008 Maintenance And Service Manual

Club Car Electric Precedent 2008 Maintenance And Service Manual (344 pages)

Brand: Club Car | Category: Golf Cars | Size: 22 MB

Table of Contents

Table of Contents
5
Section 1 - Safety
15
- General Warnings
  15
Section 2 - Vehicle Specifications
19
Section 3 - General Information
21
Section 4 - Body and Trim
25
Section 5 - Accelerator and Brake Pedal Group
47
- Pedal Group
  47
  - Pedal Group Removal
    47
  - Mcor
    49
  - Debris Shields
    49
  - Brake Return Spring
    49
  - Pawl Assembly
    49
  - Accelerator Return Spring
    50
  - Pedal Group Installation
    52
Section 6 - Wheel Brake Assemblies
53
- General Information
  53
- Brake Shoe Removal
  53
- Brake Assembly Cleaning
  57
- Brake Shoe Installation
  59
- Brake Cable Equalizer Adjustment
  62
- Brake Cluster Removal and Installation
  63
  - Brake Cluster Removal
    63
  - Brake Cluster Installation
    63
- Brake Cable Removal and Installation
  65
  - Brake Cable Removal
    65
  - Brake Cable Installation
    66
Section 7 - Steering and Front Suspension
69
- General Information
  69
- Steering Wheel
  69
  - Steering Wheel Removal
    69
  - Steering Wheel Installation
    70
- Steering Column
  70
  - Steering Column Removal
    70
  - Steering Column Installation
    71
- Rack and Pinion
  72
  - Rack and Pinion Removal
    72
  - Rack and Pinion Disassembly
    73
  - Rack and Pinion Assembly
    75
  - Rack and Pinion Installation
    76
- Front Suspension
  78
  - Lubrication
    78
  - Wheel Alignment
    78
- Front Suspension Components
  80
  - Tie Rod End Removal
    80
  - Tie Rod Installation
    80
  - Leaf Spring Removal
    81
  - Leaf Spring Installation
    81
  - Kingpin and Steering Spindle Removal
    81
  - Kingpin and Steering Spindle Installation
    81
  - Control Arm Removal
    82
  - Control Arm Installation
    82
  - Shock Absorber Removal
    82
  - Shock Absorber Installation
    82
- Front Wheel Bearings and Hubs
  85
  - Front Wheel Free Play Inspection
    85
  - Front Hub Removal
    85
  - Hub Installation
    85
Section 8 - Wheels and Tires
87
- General Information
  87
- Wheels
  87
  - Wheel Removal
    87
  - Wheel Installation
    87
- Tires
  88
  - Tire Removal
    88
  - Tire Repair
    88
  - Tire Installation
    89
Section 9 - Rear Suspension
91
Section 10 - Periodic Maintenance
97
- General Warning
  97
- General Information
  99
- Periodic Service Schedule
  99
- Periodic Lubrication Schedule
  101
Section 11 - Iq System Troubleshooting
103
- General Information
  103
- Wiring Diagrams
  104
- Troubleshooting
  109
  - Troubleshooting the Vehicle with the IQDM
    109
  - Troubleshooting Guide 1
    110
  - Troubleshooting Guide 2
    113
- Test Procedures
  115
- Communication Display Module (CDM)
  140
  - Using the CDM to Retrieve Data from the Onboard Computer
    141
- CDM Troubleshooting Guide
  141
Section 12 - Excel System Troubleshooting
143
- General Information
  143
- Wiring Diagrams
  144
- Troubleshooting
  149
  - Troubleshooting the Vehicle with the IQDM
    149
  - Troubleshooting Guide 1
    149
  - Troubleshooting Guide 2
    153
- Test Procedures
  155
- Communication Display Module (CDM)
  180
  - Using the CDM to Retrieve Data from the Onboard Computer
    181
- CDM Troubleshooting Guide
  181
Section 13 - Iq Display Module (Iqdm) and Iqdm-Pdiagnostics: Iq System
183
- Plugging the Handset into the Vehicle
  183
- Introductory Display
  184
- Menu Navigation
  184
  - Program (IQDM-P Only)
    185
  - Monitor
    185
  - Faults
    186
  - Functions
    186
  - Information
    186
  - Programmer Setup
    186
- Monitor Menu
  186
  - Throttle
    186
  - Batt Voltage
    187
  - Heatsink
    187
  - Arm Current
    187
  - Field Current
    187
  - Arm PWM
    187
- Field PWM
  187
- Speed Pulses
  187
- Foot Input
  187
- Forward Input
  188
- Reverse Input
  188
- Main Cont
  188
- Key Input
  188
- Password Tries (IQDM-P Only)
  188
- 10.3 Transaxle
  188
- 20+ Speed
  188
Faults Menu
189
- System Faults
  189
- HW Failsafe
  191
- KEY SWITCH SRO (Static Return to Off)
  191
- Throttle Fault 1
  192
- Speed Sensor
  192
- Main Welded
  192
- Main Driver on
  192
- Main Driver off
  192
- High Speed Walkaway
  192
- Main Coil FAULT
  192
- Field Missing
  193
- Hpd
  193
- Proc/Wiring
  193
- Overvoltage
  193
- Low Battery Voltage
  193
- Thermal Cutback
  193
- Motor Stall
  193
- Main Dropout
  193
- Open Armature
  194
- Incorrect Password (IQDM-P Only)
  194
- Max Password Tries (IQDM-P Only)
  194
- Fault History
  194
- Clearing Fault History
  194
Functions Menu
195
- Get Settings from Controller
  195
- Write Settings to Controller
  196
- Reset All Settings
  197
Information
198
- Model Number
  198
- Serial Number
  198
- MFG Date
  198
- Software Version
  198
Programmer Setup
198
- Program
  198
- Faults
  199
- Information
  199
IQDM and IQDM-P Handset Troubleshooting
200
Test Procedures
201
Section 14 - Iq Display Module (Iqdm) and Iqdm-Pdiagnostics: Excel System
205
Plugging the Handset into the Vehicle
205
Introductory Display
206
Menu Navigation
206
- Program (IQDM-P Only)
  207
- Monitor
  207
- Faults
  207
- Functions
  208
- Information
  208
- Programmer Setup
  208
Monitor Menu
208
- Speed
  208
- Throttle
  209
  - Batt aux Voltage
    209
  - Temperature
    209
  - Arm Current
    209
  - Field Current
    209
  - Armature PWM
    209
  - Field PWM
    209
  - Brake Volts in
    209
  - Speed Pulses
    210
  - Foot Input
    210
  - Key Input
    210
  - Forward Input
    210
  - Reverse Input
    210
  - Charger Inhibit
    210
  - Main Cont Driver
    210
  - Password Tries (IQDM-P Only)
    211
  - Odometer
    211
  - Vehicle Speeds (IQDM-P Only)
    211
  - Pedal Counters
    211
  - Fault Counters
    211
  - Fault Count Odometers
    211
  - Faults Menu
    212
    
    System Faults
    212
    
    HW Failsafe
    214
    
    Throttle Fault
    214
    
    Speed Sensor
    215
    
    Main Welded
    215
    
    Main Driver on
    215
    
    Main Driver off
    215
    
    Main Coil Open
    215
    
    Field Missing
    215
    
    Hpd
    215
    
    Overvoltage
    215
    
    Low Battery Voltage
    216
    
    Thermal Cutback
    216
    
    Motor Stall
    216
    
    Main Dropout (1 or 2)
    216
    
    Incorrect Password (IQDM-P Only)
    216
    
    Max Password Tries (IQDM-P Only)
    216
    
    Fault History
    216
    
    Clearing Fault History
    217
  - Functions Menu
    217
    
    Get Settings from Controller
    217
    
    Write Settings to Controller
    218
    
    Reset All Settings
    219
  - Information
    220
    
    Model Number
    220
    
    Serial Number
    220
    
    MFG Date
    220
    
    Software Version
    220
  - Programmer Setup
    220
    
    Program
    220
    
    Faults
    221
    
    Information
    221
  - IQDM and IQDM-P Handset Troubleshooting
    222
  - Test Procedures
    223
- Section 15 - Electrical Components
  227
  - Key Switch
    227
    
    Testing the Key Switch
    227
    
    Key Switch Removal
    227
    
    Key Switch Installation
    227
  - Battery Warning Light
    228
    
    Testing the Battery Warning Light
    228
- Battery Warning Light Removal
  228
- Battery Warning Light Installation
  229
Forward/Reverse Rocker Switch
229
Electronics Module Cover - Style a Battery Configuration
231
- Electronics Module Cover Removal
  231
- Electronics Module Cover Installation
  231
Electronics Module Cover - Styleb and C Battery Configurations
232
- Electronics Module Cover Removal
  232
- Electronics Module Cover Installation
  232
Tow/Run Switch - Style a Battery Configuration
233
- Testing the Tow/Run Switch
  233
- Tow/Run Switch Removal
  233
- Tow/Run Switch Installation
  234
Tow/Run Switch - Style B and C Battery Configurations
234
- Testing the Tow/Run Switch
  234
- Tow/Run Switch Removal
  234
- Tow/Run Switch Installation
  235
Motor Controller Output Regulator (MCOR)
235
- Testing the MCOR
  235
- MCOR Removal
  235
- MCOR Installation
  236
Reverse Buzzer
236
- Testing the Reverse Buzzer
  236
- Reverse Buzzer Removal
  236
- Reverse Buzzer Installation
  237
Electronics Module - Style a Battery Configuration
237
- Electronics Module Removal
  237
- Electronics Module Installation
  238
Electronics Module - Style B and C Battery Configurations
240
- Electronics Module Removal
  240
- Electronics Module Installation
  240
Speed Controller - Style a Battery Configuration
243
Speed Controller - Style B and C Battery Configurations
244
Solenoid - Style a Battery Configuration
245
- Testing the Solenoid
  245
- Solenoid Removal
  245
- Solenoid Installation
  245
Solenoid - Style B and C Battery Configurations
246
- Testing the Solenoid
  246
- Solenoid Removal
  246
- Solenoid Installation
  246
Onboard Computer (OBC) - Style a Battery Configuration
247
- Testing the Onboard Computer
  247
- Onboard Computer Removal
  247
- Onboard Computer Installation
  247
Onboard Computer (OBC) - Style B and C Battery Configurations
248
- Testing the Onboard Computer
  248
- Onboard Computer Removal
  248
- Onboard Computer Installation
  248
Charger Receptacle
249
- Testing the Charger Receptacle
  249
- Charger Receptacle Inspection
  249
- Charger Receptacle Removal
  249
- Charger Receptacle Installation
  250
Headlight Adjustment
251
- Aiming the Headlight Beam
  251
- Ferrite Beads - CE Mark Vehicles
  252
Section 16 - Batteries
253
- General Information
  253
- Battery Troubleshooting Chart
  254
- Battery Testing - 12 Volt
  255
  - Battery Charger Test
    255
  - On-Charge Voltage Test
    255
  - Hydrometer Test
    255
  - Discharge Test
    258
  - Battery Troubleshooting Examples
    260
- Battery Testing - 8 Volt
  261
  - Battery Charger Test
    261
  - On-Charge Voltage Test
    261
  - Hydrometer Test
    261
  - Discharge Test
    264
  - Battery Troubleshooting Examples
    266
- Battery Replacement
  267
- Battery Care
  268
- Battery Charger
  271
  - Charging Batteries
    272
  - Plug and Receptacle
    273
  - Charger Shuts off after 16 Hours
    273
  - Deep-Discharge
    273
  - Early Excessive Discharging
    274
  - Incoming AC Service
    274
  - Fleet Rotation
    274
  - Numbering Vehicles and Chargers
    274
- Single Point Watering System (SPWS)
  274
  - Initial Maintenance of the SPWS
    275
  - Watering Batteries with the SPWS
    275
- Battery Storage
  277
- Charging a Battery Pack that Has Low Voltage
  277
Section 17 - Battery Charger
279
Section 18 - Motor (Model 5Bc59Jbs6390)
281
- General Information
  281
- Motor Identification
  281
- External Motor Testing
  281
- Motor
  283
  - Motor Removal
    283
- Motor Component Testing and Inspection
  285
  - Armature
    285
  - Field Windings Inspection
    286
  - Motor Components
    286
  - Bearing Inspection
    287
  - Bearing Removal
    289
  - Bearing Installation
    289
  - Speed Sensor Magnet Inspection
    289
  - Speed Sensor Magnet Removal
    289
  - Speed Sensor Magnet Installation
    289
- Reconditioning the Motor
  289
  - Motor Specifications
    290
- Motor Assembly
  290
- Motor Installation
  292
- Motor Speed Sensor
  296
  - Testing the Motor Speed Sensor
    296
  - Motor Speed Sensor Removal
    296
  - Motor Speed Sensor Installation
    296
Section 19 - Motor (Model Ej4-4001)
299
- General Information
  299
- Motor Identification
  299
- External Motor Testing
  299
- Motor
  300
  - Motor Removal
    300
  - Motor Disassembly
    302
- Motor Component Testing and Inspection
  304
- Reconditioning the Motor
  309
  - Motor Specifications
    309
- Motor Assembly
  309
- Motor Installation
  311
Section 20 - Transaxle (Type G)
315
- Lubrication
  315
- Axle Bearing and Shaft
  315
  - Axle Shaft
    315
  - Axle Bearing
    318
- Transaxle
  319
  - Transaxle Removal
    319
- Transaxle Disassembly, Inspection, and Assembly
  322
  - Transaxle Disassembly and Inspection
    322
  - Transaxle Assembly
    324
- Transaxle Installation
  325
Section 21 - Iq Display Module Programmer (Iqdm-P): Iq System
327
- Plugging the Handset into the Vehicle
  327
- Program Menu
  327
  - Speed Setting
    328
  - Fast Accel
    329
  - Pedal up Mode
    329
  - Speed Cal
    329
  - Code A, Code B, and Code C
    329
  - Slow Pedal up
    329
  - KSI SRO Enable
    330
  - M2 Max Speed
    330
Section 22 - Iq Display Module Programmer (Iqdm-P): Excel System
331
- Plugging the Handset into the Vehicle
  331
- Program Menu
  332
  - Speed Setting
    333
  - Fast Accel
    333
  - Pedal up Mode
    333
  - Speed Cal
    333
  - S3 FWD Speed
    334
  - Code A, Code B, and Code C
    334
  - Vehicle S/N
    334
  - Vehicle Decal
    334

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