Club Car DS Villager 4 Manual

Manual Number 103373106
Edition Code 1007D1210C
DS Villager 4, Carryall 1, Turf 1
IQ System Electric Vehicles
2008-2011 IQ System
Maintenance and Service
Manual Supplement

2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement Page i
FOREWORD
Club Car vehicles are designed and built to provide the ultimate in performance efficiency; however, proper
maintenance and repair are essential for achieving maximum service life and continued safe and reliable
operation.
This supplement provides detailed information for the maintenance and repair of IQ System™ electric vehi-
cles and should be used in conjunction with the appropriate maintenance and service manual.
If you do not have the appropriate maintenance and service manual, you may order one from your local Club
Car representative. Maintenance and service manuals available include the following:
This supplement and corresponding maintenance and service manual should be thoroughly reviewed prior to
servicing the vehicle. The procedures provided must be properly implemented, and the DANGER, WARNING,
and CAUTION statements must be heeded.
This supplement was written for the trained technician who already has knowledge and skills in electrical and
mechanical repair. If the technician does not have such knowledge and skills, attempted service or repairs to
the vehicle may render the vehicle unsafe. For this reason, Club Car advises that all repairs and/or service be
performed by an authorized Club Car distributor/dealer representative or by a Club Car factory-trained tech-
nician.
It is the policy of Club Car, LLC to assist its distributors and dealers in continually updating their service knowl-
edge and facilities so they can provide prompt and efficient service for vehicle owners. Regional technical rep-
resentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and
other service publications also represent Club Car’s continuing commitment to customer support.
This supplement, used in conjunction with the appropriate maintenance and service manual, covers all
aspects of typical vehicle service; however, unique situations do sometimes occur when servicing a vehicle.
If it appears that a service question is not answered in this supplement, you may write to us at: Club Car, LLC,
P.O. Box 204658; Augusta, Georgia 30917-4658, USA, Attention: Technical Services, or contact a Club Car
Technical Service Representative at [phone], ext. 3580.
This supplement does not contain maintenance and service procedures for the battery charger. Contact your
local Club Car representative for information on how to obtain the appropriate battery charger maintenance
and service manual.
2008-2011 Turf/Carryall Vehicle Maintenance & Service Manual Publication Part No. 103373104
2008-2011 Transportation Vehicle Maintenance & Service Manual Publication Part No. 103373105
Copyright © 2007, 2009, 2010 Club Car, LLC
Club Car is a registered
trademark of Club Car, LLC
This manual effective August 1, 2007

Page ii 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement
ý WARNING
• Read Section 1 – Safety in the appropriate maintenance and service manual before attempting
any service on the vehicle.
• Before servicing vehicle, read complete section(s) and any referenced information that may
be relevant to the service or repair to be performed.
NOTE: This supplement represents the most current information at the time of publication. Club Car, LLC
is continually working to further improve its vehicles and other products. These improvements may
affect servicing procedures. Any modification and/or significant change in specifications or proce-
dures will be forwarded to all Club Car distributors/dealers and will, when applicable, appear in
future editions of this supplement.
Club Car, LLC reserves the right to change specifications and designs at any time without notice
and without the obligation of making changes to units previously sold.
There are no warranties expressed or implied in this supplement. See the limited warranty found in
the vehicle owner’s manual or write to: Club Car, LLC, P.O. Box 204658, Augusta, Georgia 30917-
4658, USA, Attention: Warranty Administration.

2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement Page iii
CONTENTS
SECTION 10 – PERIODIC MAINTENANCE
General Warning ............................................................................................................................... 10-1
Disabling The Vehicle ................................................................................................................... 10-2
Disconnecting The Batteries ......................................................................................................... 10-3
Connecting The Batteries ............................................................................................................. 10-3
General Information .......................................................................................................................... 10-4
Periodic Service Schedule ................................................................................................................ 10-4
Periodic Lubrication Schedule .......................................................................................................... 10-6
SECTION 11 – ELECTRICAL SYSTEM AND TESTING
General Information .......................................................................................................................... 11-1
Wiring Diagrams ............................................................................................................................... 11-2
Troubleshooting ................................................................................................................................ 11-10
Troubleshooting the Vehicle with the IQDM ................................................................................. 11-10
Troubleshooting Guide 1 .............................................................................................................. 11-11
Troubleshooting Guide 2 .............................................................................................................. 11-14
Test Procedures ............................................................................................................................... 11-16
Index of Test Procedures .............................................................................................................. 11-16
Communication Display Module (CDM) ............................................................................................ 11-41
Using the CDM to Retrieve Data from the Onboard Computer .................................................... 11-42
CDM Troubleshooting Guide ........................................................................................................ 11-43
SECTION 12 – IQ DISPLAY MODULE (IQDM) SERIES 2 AND IQDM-P DIAGNOSTICS
Plugging the Handset into the Vehicle .............................................................................................. 12-1
Introductory Display .......................................................................................................................... 12-2
Menu Navigation ............................................................................................................................... 12-2
Monitor Menu .................................................................................................................................... 12-4
Faults Menu ...................................................................................................................................... 12-6
Functions Menu ................................................................................................................................ 12-11
Get Settings From Controller ........................................................................................................ 12-11
Write Settings to Controller ........................................................................................................... 12-12
Reset All Settings ......................................................................................................................... 12-13
Information ........................................................................................................................................ 12-14

Page iv 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement
Programmer Setup ........................................................................................................................... 12-14
Program ....................................................................................................................................... 12-14
Faults ........................................................................................................................................... 12-14
Information ................................................................................................................................... 12-15
IQDM and IQDM-P Handset Troubleshooting .................................................................................. 12-15
Test Procedures ............................................................................................................................... 12-17
Index of Test Procedures ............................................................................................................. 12-17
SECTION 13 – ELECTRICAL COMPONENTS
Key Switch ....................................................................................................................................... 13-1
Forward/Reverse Rocker Switch ...................................................................................................... 13-3
Tow/Run Switch ............................................................................................................................... 13-5
Motor Controller Output Regulator (MCOR) ..................................................................................... 13-5
Reverse Buzzer ................................................................................................................................ 13-7
Solenoid ........................................................................................................................................... 13-7
Onboard Computer (OBC) ............................................................................................................... 13-9
Solid State Speed Controller ............................................................................................................ 13-11
Charger Receptacle ......................................................................................................................... 13-13
Receptacle Fuse Link ................................................................................................................... 13-14
Battery Warning Light ....................................................................................................................... 13-15
Pin 9 Diode ....................................................................................................................................... 13-15
Ferrite Beads – CE Mark Vehicles ................................................................................................... 13-17
2008-2010 Model Years ............................................................................................................... 13-17
Starting 2011 Model Year ............................................................................................................. 13-18
SECTION 14 – BATTERIES
General Information ......................................................................................................................... 14-1
Battery Care ..................................................................................................................................... 14-1
Preventive Maintenance ............................................................................................................... 14-1
Self-Discharge .............................................................................................................................. 14-1
Electrolyte Level ........................................................................................................................... 14-2
Water Quality ................................................................................................................................ 14-2
Vibration Damage ......................................................................................................................... 14-3
Battery Charging .............................................................................................................................. 14-4
Charger Shuts Off After 16 Hours ................................................................................................ 14-4
Deep-Discharge ........................................................................................................................... 14-4
Early Excessive Discharging ........................................................................................................ 14-4
Incoming AC Service .................................................................................................................... 14-5
Fleet Rotation ............................................................................................................................... 14-5
Numbering Vehicles and Chargers .............................................................................................. 14-5

2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement Page v
Battery Troubleshooting Chart .......................................................................................................... 14-6
Battery Testing – 8 Volt .................................................................................................................... 14-7
Battery Charger Test .................................................................................................................... 14-7
On-Charge Voltage Test ............................................................................................................... 14-7
Hydrometer Test ........................................................................................................................... 14-7
Discharge Test .............................................................................................................................. 14-9
Battery Troubleshooting Examples ............................................................................................... 14-11
Battery Testing – 12 Volt .................................................................................................................. 14-12
Battery Charger Test .................................................................................................................... 14-12
On-Charge Voltage Test ............................................................................................................... 14-12
Hydrometer Test ........................................................................................................................... 14-12
Discharge Test .............................................................................................................................. 14-14
Battery Troubleshooting Examples ............................................................................................... 14-16
Battery Storage ................................................................................................................................. 14-17
Battery Replacement ........................................................................................................................ 14-17
Charging a Battery Pack that has Low Voltage ................................................................................ 14-19
SECTION 15 – BATTERY CHARGER
Refer to the appropriate battery charger maintenance and service manual.
SECTION 16A – MOTOR (MODEL 5BC59JBS6390)
General Information .......................................................................................................................... 16a-1
Motor Identification ........................................................................................................................... 16a-1
External Motor Testing ...................................................................................................................... 16a-1
Motor ................................................................................................................................................. 16a-2
Motor Component Testing and Inspection ........................................................................................ 16a-5
Armature ....................................................................................................................................... 16a-5
Field Windings Inspection ............................................................................................................. 16a-6
Motor Components ....................................................................................................................... 16a-6
Bearing Inspection ........................................................................................................................ 16a-7
Bearing Removal .......................................................................................................................... 16a-7
Bearing Installation ....................................................................................................................... 16a-7
Speed Sensor Magnet Inspection .................................................................................................16a-9
Speed Sensor Magnet Removal ................................................................................................... 16a-9
Speed Sensor Magnet Installation ................................................................................................ 16a-9
Reconditioning the Motor .................................................................................................................. 16a-9
Motor Assembly ................................................................................................................................ 16a-10
Motor Installation .............................................................................................................................. 16a-12
Motor Speed Sensor ......................................................................................................................... 16a-15

Page vi 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement
SECTION 16B – MOTOR (MODELS EJ4-4001 AND EJ8-4001A)
General Information ......................................................................................................................... 16b-1
Motor Identification ........................................................................................................................... 16b-1
External Motor Testing ..................................................................................................................... 16b-1
Motor ................................................................................................................................................ 16b-3
Motor Removal ............................................................................................................................. 16b-3
Motor Disassembly ....................................................................................................................... 16b-5
Motor Component Testing and Inspection ....................................................................................... 16b-7
Armature Inspection and Testing ................................................................................................. 16b-7
Motor Frame and Field Windings Inspection ................................................................................ 16b-8
Motor Brush, Spring, and Terminal Insulator Inspection .............................................................. 16b-8
Reconditioning the Motor ................................................................................................................. 16b-12
Motor Assembly ............................................................................................................................... 16b-12
Motor Installation .............................................................................................................................. 16b-14
SECTION 17 – TRANSAXLE (TYPE G)
Lubrication ........................................................................................................................................ 17-1
Axle Bearing and Shaft .................................................................................................................... 17-1
Axle Shaft ..................................................................................................................................... 17-1
Axle Bearing ................................................................................................................................. 17-4
Transaxle ......................................................................................................................................... 17-5
Transaxle Removal ...................................................................................................................... 17-5
Transaxle Disassembly, Inspection, and Assembly ......................................................................... 17-7
Transaxle Disassembly and Inspection ........................................................................................ 17-7
Transaxle Assembly ..................................................................................................................... 17-9
Transaxle Installation ....................................................................................................................... 17-10
SECTION 18 – IQ DISPLAY MODULE (IQDM-P) PROGRAMMING
Plugging the Handset into the Vehicle ............................................................................................. 18-1
Program Menu ................................................................................................................................. 18-2
Speed Setting ............................................................................................................................... 18-2
Fast Accel .................................................................................................................................... 18-3
Pedal Up Mode ............................................................................................................................ 18-3
Speed Cal .................................................................................................................................... 18-3
Code A, Code B, and Code C ...................................................................................................... 18-3
SECTION i – INDEX

2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement Page 10-1
10
SECTION 10 – PERIODIC MAINTENANCE
GENERAL WARNING
The following safety statements must be heeded whenever the vehicle is being operated, repaired, or ser-
viced. Service technicians should become familiar with these general safety statements, which can be found
throughout this manual. Also, other specific safety statements appear throughout this manual and on the vehi-
cle.
ý DANGER
• Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and
service area. Ventilate when charging or using in an enclosed space. Wear a full face shield
and rubber gloves when working on or near batteries.
• Battery – Poison! Contains acid! Causes severe burns. Avoid contact with skin, eyes, or
clothing. Antidotes:
- External: Flush with water. Call a physician immediately.
- Internal: Drink large quantities of milk or water. Follow with milk of magnesia or vegetable
oil. Call a physician immediately.
- Eyes: Flush with water for 15 minutes. Call a physician immediately.
ý WARNING
• Only trained technicians should repair or service the vehicle. Anyone doing even simple
repairs or service should have knowledge and experience in electrical and mechanical repair.
• Follow the procedures exactly as stated in this manual, and heed all DANGER, WARNING, and
CAUTION statements in this manual as well as those affixed to the vehicle.
• Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle
performance or severe personal injury.
• Any modification or change to the vehicle that affects the stability or handling of the vehicle,
or increases maximum vehicle speed beyond factory specifications, could result in severe
personal injury or death.
• Check the vehicle owner’s manual for proper location of all vehicle warning decals and make
sure they are in place and are easy to read.
• Wear safety glasses or approved eye protection when servicing the vehicle. Wear a full face
shield and rubber gloves when working on or near batteries.
• Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when servicing
vehicle.
• 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.
• Use insulated tools when working near batteries or electrical connections. Use extreme
caution to avoid shorting of components or wiring.
• Turn key switch OFF and remove key, place Forward/Reverse switch in the NEUTRAL
position, and chock the wheels prior to servicing the vehicle.
• Place Tow/Run switch in the TOW position before disconnecting or connecting the batteries.
WARNING CONTINUED ON NEXT PAGE...

PERIODIC MAINTENANCE General Warning
Page 10-2 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement
10
ý WARNING
• To avoid unintentionally starting the vehicle, place Tow/Run switch in the TOW position, then
disconnect the batteries as shown (Figure 10-1, Page 10-2) and (Figure 10-2, Page 10-2).
• After disconnecting the batteries, wait 90 seconds for the controller capacitors to discharge.
• If wires are removed or replaced, make sure wiring and wire harness is properly routed and
secured. Failure to properly route and secure wiring could result in vehicle malfunction,
property damage, personal injury, or death.
• Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic
floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use lifting device to hold
vehicle in raised position. Use approved jack stands of proper weight capacity to support the
vehicle and chock the wheels that remain on the floor. When not performing a test or service
procedure that requires movement of the wheels, lock the brakes.
• For vehicles with cargo beds, remove all cargo before raising the bed or servicing the vehicle.
If the vehicle is equipped with a prop rod, ensure that it is securely engaged while bed is
raised. Do not close bed until all persons are clear of cargo bed area. Keep hands clear of all
crush areas. Do not drop cargo bed; lower gently and keep entire body clear. Failure to heed
this warning could result in severe personal injury or death.
DISABLING THE VEHICLE
1. Set the park brake.
2. Turn the key switch OFF and remove the key.
3. Place the Forward/Reverse control in the NEUTRAL position.
4. In addition, chock the wheels if servicing or repairing the vehicle..
Figure 10-1 Battery Cable Removal – DS Villager
6x8-Volt Battery Configuration
Figure 10-2 Battery Cable Removal – DS Villager
4x12-Volt Battery Configuration
(Viewed from driver side of vehicle)
1. Place TOW/RUN Switch in TOW before disconnecting or
connecting battery cables.
2. Remove negative battery cable.
3. Remove positive battery cable.
Connect battery cables in reverse order.
(Viewed from driver side of vehicle)
1. Place TOW/RUN Switch in TOW before disconnecting or
connecting battery cables.
2. Remove negative battery cable.
3. Remove positive battery cable.
Connect battery cables in reverse order.
1
2
3
5
6
4
(–)
(+)
TOWRUN
WARNING
1
2
3
1
2
3
4
3
2
1
(–)
(+)