Club Car 2009 Precedent Manual

2009ElectricPrecedent
Maintenanceand
ServiceManual
IQSystemandExcelSystemVehicles
ManualNumber103472701
EditionCode0309A00000

FOREWORD
ClubCarvehiclesaredesignedandbuilttoprovidetheultimateinperformanceefciency;however,proper
maintenanceandrepairareessentialforachievingmaximumservicelifeandcontinuedsafeandreliableoperation.
ThismanualprovidesdetailedinformationforthemaintenanceandrepairoftheelectricPrecedentvehicles,and
shouldbethoroughlyreviewedpriortoservicingthevehicle.Theproceduresprovidedhereinmustbeproperly
implemented,andtheDANGER,WARNING,andCAUTIONstatementsmustbeheeded.
Thismanualwaswrittenforthetrainedtechnicianwhoalreadypossessesknowledgeandskillsinelectricaland
mechanicalrepair.Ifthetechniciandoesnothavesuchknowledgeandskills,attemptedserviceorrepairstothe
vehiclemayrenderthevehicleunsafe.Forthisreason,ClubCaradvisesthatallrepairsand/orservicebeperformed
byanauthorizedClubCardistributor/dealerrepresentativeorbyaClubCarfactory-trainedtechnician.
ItisthepolicyofClubCar,Inc.toassistitsdistributorsanddealersincontinuallyupdatingtheirserviceknowledge
andfacilitiessotheycanprovidepromptandefcientserviceforvehicleowners.Regionaltechnicalrepresentatives,
periodicservicebulletins,maintenanceandservicemanuals,andotherservicepublicationsalsorepresentClubCar’s
continuingcommitmenttocustomersupport.
ClubCaroffersafulllineoftrainingandcontinuingeducationclassesfortechnicianswhowanttolearnmoreabout
ourproducts.Formoreinformation,contactyourlocaldealerorClubCar’sTechnicalServicesdepartmentfora
listofupcomingclasses.
Thismanualcoversallaspectsoftypicalvehicleservice;however,uniquesituationssometimesoccurwhenservicinga
vehicle.Ifitappearsthataservicequestionisnotansweredinthismanual,pleasecontactyournearestauthorized
ClubCardealerordistributorforassistance.Youmayalsowritetousat:ClubCar,Inc.,P .O.Box204658;Augusta,
GA30917–4658USA,Attention:T echnicalServices.
WARNING
•ReadSection1—Safetybeforeattemptinganyserviceonthevehicle.
•Beforeservicingvehicle,readcompletesection(s)andanyreferencedinformationthatmaybe
relevanttotheserviceorrepairtobeperformed.
NOTE:Thismanualrepresentsthemostcurrentinformationatthetimeofpublication.ClubCar,Inc.iscontinually
workingtofurtherimproveitsvehiclesandotherproducts.Theseimprovementsmayaffectservicing
procedures.Anymodicationand/orsignicantchangeinspecicationsorprocedureswillbeforwardedtoall
ClubCardealersandwill,whenapplicable,appearinfutureeditionsofthismanual.
ClubCar,Inc.reservestherighttochangespecicationsanddesignsatanytimewithoutnoticeandwithout
theobligationofmakingchangestounitspreviouslysold.
Therearenowarrantiesexpressedorimpliedinthismanual.Seethelimitedwarrantyfoundinthevehicle
owner’smanualorwritetoClubCar,Inc.,P .O.BOX204658,Augusta,Georgia30917-4658USA,Attention:
WarrantyDepartment.
Copyright©2009ClubCar,Inc.
ClubCar,Carryall,andArmorFlex
areregisteredtrademarksofClubCar,Inc.
ThismanualeffectiveAugust4,2008
2009ElectricPrecedentMaintenanceandServiceManualPagei

CONTENTS
SECTION1—SAFETY.....................................................................................................................................1-1
GeneralWarnings..........................................................................................................................................1-1
SECTION2—VEHICLESPECIFICATIONS.......................................................................................................2-1
SECTION3—GENERALINFORMATION..........................................................................................................3-1
SerialNumberIdentication............................................................................................................................3-1
SafetyCommittee..........................................................................................................................................3-2
Storage.........................................................................................................................................................3-2
PreparingtheElectricVehicleforExtendedOff-SeasonStorage...................................................................3-3
ReturningtheStoredElectricVehicletoService..........................................................................................3-3
SECTION4—BODYANDTRIM.......................................................................................................................4-1
CleaningtheVehicle......................................................................................................................................4-1
Seat..........................................................................................................................................................4-1
FrontandRearBodyRepair...........................................................................................................................4-2
StressLinesorStreaks..............................................................................................................................4-2
MinorImpactDamage/Deformations...........................................................................................................4-2
MinorScratchesandSurfaceBlemishes.....................................................................................................4-3
Gouges,Punctures,Tears,LargeScratches,andAbrasions.........................................................................4-3
FrontBody....................................................................................................................................................4-3
FrontBodyRemoval..................................................................................................................................4-3
FrontBodyInstallation...............................................................................................................................4-3
FrontBumper................................................................................................................................................4-5
InstrumentPanel...........................................................................................................................................4-6
InstrumentPanelRemoval.........................................................................................................................4-6
InstrumentPanelInstallation......................................................................................................................4-6
FloorMatandRetainers.................................................................................................................................4-7
FloorMatRetainerRemoval.......................................................................................................................4-7
FloorMatRetainerInstallation....................................................................................................................4-7
KickPlateandChargerReceptacleBezel.......................................................................................................4-8
KickPlateandChargerReceptacleBezelRemoval.....................................................................................4-8
KickPlateandChargerReceptacleBezelInstallation...................................................................................4-8
RearBody–Two-PassengerVehicles.............................................................................................................4-9
UniversalAccessoryMounting....................................................................................................................4-9
BackrestandStructuralAccessoryModule(SAM).......................................................................................4-9
RearBodyComponents(Two-Passenger)..................................................................................................4-11
RearBody–Four-PassengerVehicles..........................................................................................................4-13
SeatBacks..............................................................................................................................................4-13
SeatSupport...........................................................................................................................................4-13
FootDeck...............................................................................................................................................4-14
RearBodyComponents(Four-Passenger)................................................................................................4-15
Canopy–Two-Passenger............................................................................................................................4-16
Two-PassengerCanopyRemoval.............................................................................................................4-16
Two-PassengerCanopyInstallation..........................................................................................................4-18
Canopy–Four-Passenger...........................................................................................................................4-20
Four-PassengerCanopyRemoval............................................................................................................4-20
Four-PassengerCanopyInstallation.........................................................................................................4-20
SECTION5—ACCELERATORANDBRAKEPEDALGROUP..........................................................................5-1
PedalGroup..................................................................................................................................................5-1
PedalGroupRemoval................................................................................................................................5-1
ThrottlePositionSensor.............................................................................................................................5-3
DebrisShields...........................................................................................................................................5-3
AcceleratorPedalRemoval........................................................................................................................5-3
2009ElectricPrecedentMaintenanceandServiceManualPageiii

AcceleratorPedalInstallation.....................................................................................................................5-3
BrakePedalRemoval................................................................................................................................5-5
BrakePedalInstallation.............................................................................................................................5-5
PedalGroupInstallation.............................................................................................................................5-5
SECTION6—WHEELBRAKEASSEMBLIES...................................................................................................6-1
GeneralInformation.......................................................................................................................................6-1
BrakeShoeRemoval.....................................................................................................................................6-1
BrakeAssemblyCleaning..............................................................................................................................6-5
BrakeShoeInstallation..................................................................................................................................6-7
BrakeCableEqualizerAdjustment................................................................................................................6-10
BrakeClusterRemovalandInstallation..........................................................................................................6-11
BrakeClusterRemoval.............................................................................................................................6-11
BrakeClusterInstallation..........................................................................................................................6-11
BrakeCableRemovalandInstallation...........................................................................................................6-13
BrakeCableRemoval..............................................................................................................................6-13
BrakeCableInstallation...........................................................................................................................6-14
SECTION7—STEERINGANDFRONTSUSPENSION......................................................................................7-1
GeneralInformation.......................................................................................................................................7-1
SteeringWheel..............................................................................................................................................7-1
SteeringWheelRemoval............................................................................................................................7-1
SteeringWheelInstallation.........................................................................................................................7-2
SteeringColumn............................................................................................................................................7-2
SteeringColumnRemoval..........................................................................................................................7-2
SteeringColumnInstallation.......................................................................................................................7-3
RackandPinion............................................................................................................................................7-4
RackandPinionRemoval..........................................................................................................................7-4
RackandPinionDisassembly....................................................................................................................7-5
RackandPinionAssembly.........................................................................................................................7-7
RackandPinionInstallation.......................................................................................................................7-8
FrontSuspension........................................................................................................................................7-10
Lubrication..............................................................................................................................................7-10
WheelAlignment.....................................................................................................................................7-10
FrontSuspensionComponents.....................................................................................................................7-12
TieRodEndRemoval..............................................................................................................................7-12
TieRodInstallation..................................................................................................................................7-12
LeafSpringRemoval...............................................................................................................................7-13
LeafSpringInstallation.............................................................................................................................7-13
KingpinandSteeringSpindleRemoval.....................................................................................................7-13
KingpinandSteeringSpindleInstallation...................................................................................................7-13
ControlArmRemoval...............................................................................................................................7-14
ControlArmInstallation............................................................................................................................7-14
ShockAbsorberRemoval.........................................................................................................................7-14
ShockAbsorberInstallation......................................................................................................................7-14
FrontWheelBearingsandHubs...................................................................................................................7-17
FrontWheelFreePlayInspection.............................................................................................................7-17
FrontHubRemoval..................................................................................................................................7-17
HubInstallation........................................................................................................................................7-17
SECTION8—WHEELSANDTIRES.................................................................................................................8-1
GeneralInformation.......................................................................................................................................8-1
Wheels.........................................................................................................................................................8-1
WheelRemoval.........................................................................................................................................8-1
WheelInstallation......................................................................................................................................8-1
Tires.............................................................................................................................................................8-2
TireRemoval.............................................................................................................................................8-2
TireRepair................................................................................................................................................8-2
TireInstallation..........................................................................................................................................8-3
Pageiv2009ElectricPrecedentMaintenanceandServiceManual

SECTION9—REARSUSPENSION..................................................................................................................9-1
GeneralInformation.......................................................................................................................................9-1
ShockAbsorbers...........................................................................................................................................9-1
ShockAbsorberRemovalandInspection....................................................................................................9-1
ShockAbsorberInstallation........................................................................................................................9-1
LeafSprings(Two-PassengerVehicles)..........................................................................................................9-2
LeafSpringRemoval(Two-PassengerVehicles)..........................................................................................9-2
LeafSpringInstallation(Two-PassengerVehicles).......................................................................................9-3
LeafSprings(Four-PassengerVehicles).........................................................................................................9-4
LeafSpringRemoval(Four-PassengerVehicles).........................................................................................9-4
LeafSpringInstallation(Four-PassengerVehicles)......................................................................................9-5
SECTION10—PERIODICMAINTENANCE.....................................................................................................10-1
GeneralWarning.........................................................................................................................................10-1
GeneralInformation.....................................................................................................................................10-3
PeriodicServiceSchedule............................................................................................................................10-3
PeriodicLubricationSchedule......................................................................................................................10-6
SECTION11—IQSYSTEMTROUBLESHOOTING..........................................................................................11-1
GeneralInformation......................................................................................................................................11-1
WiringDiagrams...........................................................................................................................................11-2
Troubleshooting............................................................................................................................................11-7
TroubleshootingtheVehiclewiththeIQDM................................................................................................11-7
TroubleshootingGuide1...........................................................................................................................11-8
TroubleshootingGuide2.........................................................................................................................11-11
TestProcedures.........................................................................................................................................11-13
CommunicationDisplayModule(CDM)........................................................................................................11-35
UsingtheCDMtoRetrieveDatafromtheOnboardComputer...................................................................11-36
CDMTroubleshootingGuide.......................................................................................................................11-37
SECTION12—EXCELSYSTEMTROUBLESHOOTING..................................................................................12-1
GeneralInformation.....................................................................................................................................12-1
WiringDiagrams..........................................................................................................................................12-2
Troubleshooting...........................................................................................................................................12-7
TroubleshootingtheVehiclewiththeIQDM...............................................................................................12-7
TroubleshootingGuide1..........................................................................................................................12-7
TroubleshootingGuide2.........................................................................................................................12-11
TestProcedures.........................................................................................................................................12-13
CommunicationDisplayModule(CDM)........................................................................................................12-35
UsingtheCDMtoRetrieveDatafromtheOnboardComputer...................................................................12-36
CDMTroubleshootingGuide.......................................................................................................................12-37
SECTION13—IQDISPLAYMODULE(IQDM)ANDIQDM-PDIAGNOSTICS:IQSYSTEM...............................13-1
PluggingtheHandsetintotheVehicle...........................................................................................................13-1
IntroductoryDisplay.....................................................................................................................................13-1
MenuNavigation.........................................................................................................................................13-2
Program(IQDM-Ponly)...........................................................................................................................13-3
Monitor...................................................................................................................................................13-3
Faults.....................................................................................................................................................13-4
Functions................................................................................................................................................13-4
Information..............................................................................................................................................13-4
ProgrammerSetup..................................................................................................................................13-4
MonitorMenu..............................................................................................................................................13-4
Throttle...................................................................................................................................................13-4
BattVoltage.............................................................................................................................................13-5
Heatsink..................................................................................................................................................13-5
ArmCurrent............................................................................................................................................13-5
FieldCurrent...........................................................................................................................................13-5
ArmPWM...............................................................................................................................................13-5
2009ElectricPrecedentMaintenanceandServiceManualPagev

FieldPWM..............................................................................................................................................13-5
SpeedPulses..........................................................................................................................................13-5
FootInput...............................................................................................................................................13-5
ForwardInput..........................................................................................................................................13-6
ReverseInput..........................................................................................................................................13-6
MainCont...............................................................................................................................................13-6
KeyInput................................................................................................................................................13-6
PasswordTries(IQDM-Ponly).................................................................................................................13-6
10.3Transaxle.........................................................................................................................................13-6
20+Speed..............................................................................................................................................13-6
FaultsMenu................................................................................................................................................13-7
SystemFaults.........................................................................................................................................13-7
HWFailsafe............................................................................................................................................13-9
KEYSWITCHSRO(StaticReturntoOff)..................................................................................................13-9
ThrottleFault1.......................................................................................................................................13-10
Speedsensor.........................................................................................................................................13-10
MainWelded..........................................................................................................................................13-10
MainDriverOn.......................................................................................................................................13-10
MainDriverOff.......................................................................................................................................13-10
HighSpeedWalkaway............................................................................................................................13-10
MainCoilFAULT.....................................................................................................................................13-10
FieldMissing..........................................................................................................................................13-11
HPD......................................................................................................................................................13-11
Proc/Wiring............................................................................................................................................13-11
Overvoltage............................................................................................................................................13-11
LowBatteryVoltage................................................................................................................................13-11
ThermalCutback....................................................................................................................................13-11
MotorStall..............................................................................................................................................13-11
MainDropout.........................................................................................................................................13-11
OpenArmature.......................................................................................................................................13-12
IncorrectPassword(IQDM-Ponly)...........................................................................................................13-12
MaxPasswordTries(IQDM-Ponly).........................................................................................................13-12
FaultHistory...........................................................................................................................................13-12
ClearingFaultHistory.............................................................................................................................13-12
FunctionsMenu..........................................................................................................................................13-13
GetSettingsFromController...................................................................................................................13-13
WriteSettingstoController......................................................................................................................13-14
ResetAllSettings...................................................................................................................................13-15
Information.................................................................................................................................................13-16
ModelNumber........................................................................................................................................13-16
SerialNumber........................................................................................................................................13-16
MFGDate..............................................................................................................................................13-16
SoftwareVersion....................................................................................................................................13-16
ProgrammerSetup.....................................................................................................................................13-17
Program.................................................................................................................................................13-17
Faults....................................................................................................................................................13-17
Information.............................................................................................................................................13-17
IQDMandIQDM-PHandsetTroubleshooting...............................................................................................13-18
TestProcedures.........................................................................................................................................13-19
SECTION14—IQDISPLAYMODULE(IQDM)ANDIQDM-PDIAGNOSTICS:EXCELSYSTEM.......................14-1
PluggingtheHandsetintotheVehicle...........................................................................................................14-1
IntroductoryDisplay.....................................................................................................................................14-2
MenuNavigation.........................................................................................................................................14-2
Program(IQDM-Ponly)...........................................................................................................................14-3
Monitor...................................................................................................................................................14-3
Faults.....................................................................................................................................................14-4
Functions................................................................................................................................................14-4
Information..............................................................................................................................................14-4
ProgrammerSetup..................................................................................................................................14-4
MonitorMenu..............................................................................................................................................14-4
Speed.....................................................................................................................................................14-5
Throttle...................................................................................................................................................14-5
Pagevi2009ElectricPrecedentMaintenanceandServiceManual

BattAuxVoltage......................................................................................................................................14-5
Temperature............................................................................................................................................14-5
ArmCurrent............................................................................................................................................14-5
FieldCurrent...........................................................................................................................................14-5
ArmaturePWM........................................................................................................................................14-5
FieldPWM..............................................................................................................................................14-5
BrakeVoltsIn..........................................................................................................................................14-6
SpeedPulses..........................................................................................................................................14-6
FootInput...............................................................................................................................................14-6
KeyInput................................................................................................................................................14-6
ForwardInput..........................................................................................................................................14-6
ReverseInput..........................................................................................................................................14-6
ChargerInhibit.........................................................................................................................................14-6
MainContDriver.....................................................................................................................................14-7
PasswordTries(IQDM-POnly).................................................................................................................14-7
Odometer................................................................................................................................................14-7
VehicleSpeeds(IQDM-POnly).................................................................................................................14-7
PedalCounters........................................................................................................................................14-7
FaultCounters.........................................................................................................................................14-7
FaultCountOdometers............................................................................................................................14-7
FaultsMenu................................................................................................................................................14-8
SystemFaults.........................................................................................................................................14-8
HWFailsafe...........................................................................................................................................14-10
ThrottleFault..........................................................................................................................................14-10
Speedsensor.........................................................................................................................................14-11
MainWelded..........................................................................................................................................14-11
MainDriverOn.......................................................................................................................................14-11
MainDriverOff.......................................................................................................................................14-11
MainCoilOpen.......................................................................................................................................14-11
FieldMissing..........................................................................................................................................14-11
HPD......................................................................................................................................................14-11
Overvoltage............................................................................................................................................14-11
LowBatteryVoltage................................................................................................................................14-12
ThermalCutback....................................................................................................................................14-12
MotorStall..............................................................................................................................................14-12
MainDropout(1or2)..............................................................................................................................14-12
IncorrectPassword(IQDM-Ponly)...........................................................................................................14-12
MaxPasswordTries(IQDM-Ponly).........................................................................................................14-12
FaultHistory...........................................................................................................................................14-12
ClearingFaultHistory.............................................................................................................................14-13
FunctionsMenu..........................................................................................................................................14-13
GetSettingsFromController...................................................................................................................14-13
WriteSettingstoController......................................................................................................................14-14
ResetAllSettings...................................................................................................................................14-15
Information.................................................................................................................................................14-16
ModelNumber........................................................................................................................................14-16
SerialNumber........................................................................................................................................14-16
MFGDate..............................................................................................................................................14-16
SoftwareVersion....................................................................................................................................14-16
ProgrammerSetup.....................................................................................................................................14-17
Program.................................................................................................................................................14-17
Faults....................................................................................................................................................14-17
Information.............................................................................................................................................14-17
IQDMandIQDM-PHandsetTroubleshooting...............................................................................................14-18
TestProcedures.........................................................................................................................................14-19
SECTION15—ELECTRICALCOMPONENTS................................................................................................15-1
KeySwitch..................................................................................................................................................15-1
TestingtheKeySwitch.............................................................................................................................15-1
KeySwitchRemoval................................................................................................................................15-1
KeySwitchInstallation.............................................................................................................................15-1
BatteryWarningLight...................................................................................................................................15-2
TestingtheBatteryWarningLight..............................................................................................................15-2
2009ElectricPrecedentMaintenanceandServiceManualPagevii

BatteryWarningLightRemoval................................................................................................................15-2
BatteryWarningLightInstallation..............................................................................................................15-3
Forward/ReverseRockerSwitch...................................................................................................................15-3
TestingtheForward/ReverseRockerSwitch..............................................................................................15-3
Forward/ReverseRockerSwitchRemoval.................................................................................................15-3
Forward/ReverseRockerSwitchInstallation..............................................................................................15-4
ElectronicsModuleCover.............................................................................................................................15-5
ElectronicsModuleCoverRemoval..........................................................................................................15-5
ElectronicsModuleCoverInstallation........................................................................................................15-5
Tow/RunSwitch...........................................................................................................................................15-6
TestingtheTow/RunSwitch......................................................................................................................15-6
Tow/RunSwitchRemoval.........................................................................................................................15-6
Tow/RunSwitchInstallation......................................................................................................................15-6
ThrottlePositionSensor...............................................................................................................................15-7
TestingtheThrottlePositionSensor..........................................................................................................15-7
ThrottlePositionSensorReplacement......................................................................................................15-7
ReverseBuzzer...........................................................................................................................................15-8
TestingtheReverseBuzzer......................................................................................................................15-8
ReverseBuzzerRemoval.........................................................................................................................15-8
ReverseBuzzerInstallation......................................................................................................................15-8
ElectronicsModule......................................................................................................................................15-9
ElectronicsModuleRemoval....................................................................................................................15-9
ElectronicsModuleInstallation.................................................................................................................15-9
SpeedController........................................................................................................................................15-12
TestingtheSolidStateSpeedController..................................................................................................15-12
SpeedControllerRemoval......................................................................................................................15-12
SpeedControllerInstallation....................................................................................................................15-12
Solenoid.....................................................................................................................................................15-13
TestingtheSolenoid...............................................................................................................................15-13
SolenoidRemoval..................................................................................................................................15-13
SolenoidInstallation................................................................................................................................15-13
OnboardComputer(OBC)...........................................................................................................................15-14
TestingtheOnboardComputer................................................................................................................15-14
OnboardComputerRemoval...................................................................................................................15-14
OnboardComputerInstallation................................................................................................................15-14
ChargerReceptacle....................................................................................................................................15-15
TestingtheChargerReceptacle...............................................................................................................15-15
ChargerReceptacleInspection................................................................................................................15-15
ChargerReceptacleRemoval..................................................................................................................15-15
ChargerReceptacleInstallation...............................................................................................................15-16
HeadlightAdjustment..................................................................................................................................15-16
AimingtheHeadlightBeam.....................................................................................................................15-16
FerriteBeads–CEMarkVehicles...............................................................................................................15-18
SECTION16—BATTERIES............................................................................................................................16-1
GeneralInformation.....................................................................................................................................16-1
BatteryTroubleshootingChart......................................................................................................................16-2
BatteryTesting–12Volt...............................................................................................................................16-3
BatteryChargerTest................................................................................................................................16-3
On-ChargeVoltageT est...........................................................................................................................16-3
HydrometerTest......................................................................................................................................16-3
DischargeTest........................................................................................................................................16-6
BatteryTroubleshootingExamples............................................................................................................16-8
BatteryTesting–8Volt................................................................................................................................16-9
BatteryChargerTest................................................................................................................................16-9
On-ChargeVoltageT est...........................................................................................................................16-9
HydrometerTest......................................................................................................................................16-9
DischargeTest.......................................................................................................................................16-12
BatteryTroubleshootingExamples...........................................................................................................16-14
BatteryReplacement..................................................................................................................................16-15
BatteryCare...............................................................................................................................................16-16
BatteryCare–VehiclesEquippedwiththeSingle-PointWateringSystem..................................................16-16
BatteryCare–VehiclesWithouttheSingle-PointWateringSystem............................................................16-17
Pageviii2009ElectricPrecedentMaintenanceandServiceManual

Self-Discharge........................................................................................................................................16-18
ElectrolyteLevel.....................................................................................................................................16-18
MineralContent......................................................................................................................................16-19
VibrationDamage...................................................................................................................................16-19
BatteryCharger..........................................................................................................................................16-19
ChargingBatteries..................................................................................................................................16-20
PlugandReceptacle...............................................................................................................................16-21
ChargerShutsOffAfter16Hours............................................................................................................16-21
Deep-Discharge.....................................................................................................................................16-21
EarlyExcessiveDischarging...................................................................................................................16-22
IncomingACService..............................................................................................................................16-22
FleetRotation.........................................................................................................................................16-22
NumberingVehiclesandChargers...........................................................................................................16-22
SinglePointWateringSystem(SPWS).........................................................................................................16-22
InitialMaintenanceoftheSPWS..............................................................................................................16-23
WateringBatterieswiththeSPWS...........................................................................................................16-23
BatteryStorage..........................................................................................................................................16-25
ChargingaBatteryPackthathasLowVoltage.............................................................................................16-25
SECTION17—BATTERYCHARGER.............................................................................................................17-1
SECTION18—MOTOR(MODELEJ4-4001ANDEJ8-4001A).........................................................................18-1
GeneralInformation.....................................................................................................................................18-1
MotorIdentication......................................................................................................................................18-1
ExternalMotorTesting.................................................................................................................................18-1
Motor..........................................................................................................................................................18-3
MotorRemoval........................................................................................................................................18-3
MotorDisassembly..................................................................................................................................18-4
MotorComponentTestingandInspection......................................................................................................18-7
ArmatureInspectionandTesting...............................................................................................................18-7
MotorFrameandFieldWindingsInspection..............................................................................................18-9
MotorBrush,Spring,andTerminalInsulatorInspection..............................................................................18-9
ReconditioningtheMotor............................................................................................................................18-12
MotorSpecications...............................................................................................................................18-12
MotorAssembly..........................................................................................................................................18-12
MotorInstallation........................................................................................................................................18-14
SECTION19—TRANSAXLE(TYPEG)..........................................................................................................19-1
Lubrication..................................................................................................................................................19-1
AxleBearingandShaft................................................................................................................................19-1
AxleShaft...............................................................................................................................................19-1
AxleBearing............................................................................................................................................19-4
Transaxle....................................................................................................................................................19-5
TransaxleRemoval..................................................................................................................................19-5
TransaxleDisassembly,Inspection,andAssembly.........................................................................................19-8
TransaxleDisassemblyandInspection......................................................................................................19-8
TransaxleAssembly................................................................................................................................19-10
TransaxleInstallation..................................................................................................................................19-11
SECTION20—IQDISPLAYMODULEPROGRAMMER(IQDM-P):IQSYSTEM...............................................20-1
PluggingtheHandsetintotheVehicle...........................................................................................................20-1
ProgramMenu............................................................................................................................................20-2
SpeedSetting..........................................................................................................................................20-3
FastAccel...............................................................................................................................................20-3
PedalUpMode........................................................................................................................................20-3
SpeedCal...............................................................................................................................................20-3
CodeA,CodeB,andCodeC...................................................................................................................20-3
SlowPedalUp.........................................................................................................................................20-4
KSISROEnable......................................................................................................................................20-4
M2MaxSpeed........................................................................................................................................20-4
2009ElectricPrecedentMaintenanceandServiceManualPageix

SECTION21—IQDISPLAYMODULEPROGRAMMER(IQDM-P):EXCELSYSTEM........................................21-1
PluggingtheHandsetintotheVehicle...........................................................................................................21-1
ProgramMenu............................................................................................................................................21-2
SpeedSetting..........................................................................................................................................21-3
FastAccel...............................................................................................................................................21-3
PedalUpMode........................................................................................................................................21-3
SpeedCal...............................................................................................................................................21-3
S3FWDSpeed.......................................................................................................................................21-4
CodeA,CodeB,andCodeC...................................................................................................................21-4
VehicleS/N.............................................................................................................................................21-4
VehicleDecal..........................................................................................................................................21-4
SECTIONi—INDEX
Pagex2009ElectricPrecedentMaintenanceandServiceManual

SECTION1—SAFETY1
ToensurethesafetyofthoseservicingClubCarvehicles,andtoprotectthevehiclesfrompossibledamageresulting
fromimproperserviceormaintenance,theproceduresinthismanualmustbefollowed.
ItisimportanttonotethatthroughoutthismanualtherearestatementslabeledDANGER,WARNING,orCAUTION.
Thesespecialstatementsrelatetospecicsafetyissues,andmustberead,understood,andheededbefore
proceedingwithprocedures.TherearestatementslabeledNOTE,whichprovideotheressentialserviceor
maintenanceinformation.
DANGER
•ADANGERindicatesanimmediatehazardthatwillresultinseverepersonalinjuryordeath.
WARNING
•AWARNINGindicatesanimmediatehazardthatcouldresultinseverepersonalinjuryordeath.
CAUTION
•ACAUTIONwiththesafetyalertsymbolindicatesahazardorunsafepracticethatcouldresultin
minorpersonalinjury.
CAUTION
•ACAUTIONwithoutthesafetyalertsymbolindicatesapotentiallyhazardoussituationthatcould
resultinpropertydamage.
GENERALWARNINGS
Thefollowingsafetystatementsmustbeheededwheneverthevehicleisbeingoperated,repaired,orserviced.Other
specicsafetystatementsappearthroughoutthismanualandonthevehicle.
DANGER
•Battery–Explosivegases!Donotsmoke.Keepsparksandamesawayfromthevehicleandservice
area.Ventilatewhenchargingoroperatingvehicleinanenclosedarea.Wearafullfaceshieldand
rubbergloveswhenworkingonornearbatteries.
•Battery–Poison!Containsacid!Causessevereburns.Avoidcontactwithskin,eyes,orclothing.
Antidotes:
–External:Flushwithwater.Callaphysicianimmediately.
–Internal:Drinklargequantitiesofmilkorwater.Followwithmilkofmagnesiaorvegetable
oil.Callaphysicianimmediately.
–Eyes:Flushwithwaterfor15minutes.Callaphysicianimmediately.
2009ElectricPrecedentMaintenanceandServiceManualPage1-1

1GeneralWarningsSAFETY
WARNING
•Onlytrainedtechniciansshouldserviceorrepairthevehicleorbatterycharger.Anyonedoingeven
simplerepairsorserviceshouldhaveknowledgeandexperienceinelectricalandmechanicalrepair.
Theappropriateinstructionsmustbeusedwhenperformingmaintenance,service,oraccessory
installation.
•Followtheproceduresexactlyasstatedinthismanual,andheedallDANGER,WARNING,and
CAUTIONstatementsinthismanualaswellasthoseonthevehicleandbatterycharger.
•Liftonlyoneendofthevehicleatatime.Useasuitableliftingdevice(chainhoistorhydraulicoor
jack)with1000lb.(454kg)minimumliftingcapacity.Donotuseliftingdevicetoholdvehicleinraised
position.Useapprovedjackstandsofproperweightcapacitytosupportthevehicleandchock
thewheelsthatremainontheoor.Whennotperformingatestorserviceprocedurethatrequires
movementofthewheels,lockthebrakes.
•Improperuseofthevehicleorfailuretoproperlymaintainitcouldresultindecreasedvehicle
performance,severepersonalinjury,ordeath.
•Anymodicationorchangetothevehiclethataffectsthestabilityorhandlingofthevehicle,or
increasesmaximumvehiclespeedbeyondfactoryspecications,couldresultinseverepersonal
injuryordeath.
•Checkthevehicleforproperlocationofallvehiclesafetyandoperationdecalsandmakesuretheyare
inplaceandareeasytoread.
•Wearsafetyglassesorapprovedeyeprotectionwhenservicingthevehicleorbatterycharger.Weara
fullfaceshieldandrubbergloveswhenworkingonornearbatteries.
•Donotwearlooseclothingorjewelrysuchasrings,watches,chains,etc.,whenservicingthe
vehicleorbatterycharger.
•Useinsulatedtoolswhenworkingnearbatteriesorelectricalconnections.Useextremecautionto
avoidshortingofcomponentsorwiring.
•Priortoleavingthevehicleunattendedorservicingthevehicle,settheparkbrake,turnthekeyswitch
OFF,removethekey,andplacetheForward/ReverseswitchintheNEUTRALposition.Chockthe
wheelswhenservicingthevehicle.
•Disconnectchargerplugbeforeservicingvehicle.
•PlaceTow/RunswitchintheTOWpositionbeforedisconnectingorconnectingthebatteries.Failureto
heedthiswarningcouldresultinabatteryexplosionorseverepersonalinjury.
•Toavoidunintentionallystartingthevehicle,disconnectthebatteriesasshown(Figure1-1,Page1-3)
and(Figure1-2,Page1-3).
•Afterdisconnectingthebatteries,wait90secondsforthecontrollercapacitorstodischarge.
•Donotleavechildrenunattendedonvehicle.
Page1-22009ElectricPrecedentMaintenanceandServiceManual

SAFETYGeneralWarnings1
(+)
2
1
POS
NEG
POS
NEG
2
4
1
3
POS
POS
NEG
NEG
(–)
3
(Viewedfromdriversideofvehicle)
1.PlaceTOW/RUNSwitchinTOWbeforedisconnectingorconnecting
batterycables.
2.Removenegativebatterycable.
3.Removepositivebatterycable.
Connectbatterycablesinreverseorder.
TOW
RUN
2
3
4
5
6
+
1
1
(–)
(+)
3
2
(Viewedfromdriversideofvehicle)
1.PlaceTOW/RUNSwitchinTOWbeforedisconnectingorconnecting
batterycables.
2.Removenegativebatterycable.
3.Removepositivebatterycable.
Connectbatterycablesinreverseorder.
422
Figure1-1BatteryCableRemoval–4x12VoltBattery
Conguration
49A
Figure1-2BatteryCableRemoval–6x8VoltBattery
Conguration
2009ElectricPrecedentMaintenanceandServiceManualPage1-3

SECTION2—VEHICLESPECIFICATIONS2
SPECIFICATIONS
TWO-
PASSENGER
ELECTRIC
VEHICLE
FOUR-
PASSENGER
ELECTRIC
VEHICLE
POWERSOURCE
Drivemotor:Directdrive,48voltsDC,shunt-wound,3.1hp••
Transaxle:Doublereductionhelicalgearwith12.3:1directdriveaxle••
Electricalsystem:48voltsDC,reducedspeedreverse••
Batteries:Highcapacity,deepcycle••
Charger:Automatic,48-volt;ULandCSAlisted••
STEERING/SUSPENSION/BRAKES
Steering:Self-adjustingrackandpinion••
Suspension:Frontandreartaperedmono-leafspringswithdualhydraulicshocks••
Brakes:Dualrearwheelself-adjustingbrakeswithcastirondrumsandsinglebrakepedalwith
automatic-releaseparkbrake••
BODY/CHASSIS
Frame/Chassis:Aluminumandcomposite••
Frontandrearbody:DupontSurlyn©Reections••
Bodynish:High-glossmolded-incolor••
Tires:18x8.5–8tubeless,4plyrated••
DIMENSIONS/WEIGHT
Overalllength91.5in.(232cm)104in.(264cm)
Overallwidth47.25in.
(120cm)
47.25in.
(120cm)
Overallheight(withcanopy)68.5in.(174cm)71in.(180cm)
Overallheight(atsteeringwheel)48.0in.(122cm)48.0in.(122cm)
Wheelbase65.5in.(166cm)65.5in.(166cm)
Groundclearance4.5in.(11cm)4.5in.(11cm)
Frontwheeltread34.5in.(88cm)34.5in.(88cm)
Rearwheeltread38.6in.(98cm)38.6in.(98cm)
Weight(standardelectricvehiclewithcanopy,withbatteries)
Forvehicleswithsix8-voltbatteries,add54lb.(24.5kg).855lb.(388kg)970lb.(440kg)
Forwardspeed12-15mph(19-24km/h)
Curbclearancecircle(diameter)17ft-4in.(528cm)17ft-4in.(528cm)
Standardseatingcapacity24
LIQUIDCAPACITIES
Transaxle22oz.
(.67liters)
22oz.
(.67liters)
TABLECONTINUEDONNEXTPAGE
2009ElectricPrecedentMaintenanceandServiceManualPage2-1

2GeneralWarningsVEHICLESPECIFICATIONS
SPECIFICATIONS
TWO-
PASSENGER
ELECTRIC
VEHICLE
FOUR-
PASSENGER
ELECTRIC
VEHICLE
TIREPRESSURE
Frontandrear18-20psi(1.24-1.38
bars)
18-20psi(1.24-1.38
bars)
Page2-22009ElectricPrecedentMaintenanceandServiceManual

SECTION3—GENERALINFORMATION3
DANGER
•SeeGeneralWarningsonpage1-1.
WARNING
•SeeGeneralWarningsonpage1-1.
Importantfeaturesuniquetothedifferentmodelscoveredinthismanualarehighlighted.ClubCar,Inc.recommends
theowner/operatorreadandunderstandthismanualandpayspecialattentiontofeaturesspecictotheirvehicle(s).
Refertotheowner’smanualprovidedwiththevehicleforinformationonthefollowingtopics:
•Pre-OperationandDailySafetyChecklist
•ControlsandIndicators
•DrivingInstructions
•Towing
•TransportingonaTrailer
•SubsequentOwnerRegistration
•Warranties
SERIALNUMBERIDENTIFICATION
Theserialnumberofthevehicleisprintedonabarcodedecalmountedbelowthepassengersidecupholder
(Figure3-1,Page3-2).
Thetwolettersatthebeginningoftheserialnumberindicatethevehiclemodel.Thefollowingfourdigitsindicatethe
modelyearandproductionweekduringwhichthevehiclewasbuilt.Thesixdigitsfollowingthehyphenrepresentthe
uniquesequentialnumberassignedtoeachvehiclebuiltwithinagivenmodelyear.
NOTE:Havethevehicleserialnumberavailablewhenorderingpartsormakinginquiries.
ExcelSystemvehicleshaveserialnumberprexPD,PH,PJ,PK,PU,orPV.
2009ElectricPrecedentMaintenanceandServiceManualPage3-1

3SafetyCommitteeGENERALINFORMATION
P.O. B OX 20 4658
AUGUSTA, GA 3 091 7
SERIAL NUMBER
PR0601-123456
425
Figure3-1SerialNumberDecal
SAFETYCOMMITTEE
Ifthegolfcaristoberentedorispartofaeet,westronglyrecommendthatasafetycommitteebeappointed.Oneof
themainconcernsofthiscommitteeshouldbethesafeoperationofthegolfcars.
Thisshouldincludeataminimum:
•Wheregolfcarsshouldbedriven.
•Ensuringthatproperwarningsofdrivinghazardsaredisplayedandvisible.Seebelowforlistofsignsavailable
fromClubCarServicePartsDepartment.
•Whoshouldandwhoshouldnotdrivegolfcars.
•Instructingrsttimedrivers.
•Maintaininggolfcarsinasafedrivingcondition
•Howvariousrulesaretobeenforced.
Thesafetycommitteeshouldincludealltheseitemsandsuchothersasthecommitteefeelsnecessaryorappropriate.
STORAGE
SeeGeneralWarningsonpage1-1.
WARNING
•TurnthekeyswitchOFF,removethekey,andleavetheForward/ReverseswitchintheNEUTRAL
positionduringstorage.Thisistopreventunintentionallystartingthevehicleorarehazard.
•Donotattempttochargefrozenbatteriesorbatterieswithbulgedcases.Discardthebattery.Frozen
batteriescanexplode.
Page3-22009ElectricPrecedentMaintenanceandServiceManual