Club car Electric precedent 2008 Manual

2008ElectricPrecedent

Maintenanceand

ServiceManual

IQSystemandExcelSystemVehicles

ManualNumber103373101

EditionCode0907D0309C

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,

vehicleserviceseminars,periodicservicebulletins,maintenanceandservicemanuals,andotherservicepublications

alsorepresentClubCar’scontinuingcommitmenttocustomersupport.

ClubCaroffersafulllineoftrainingandcontinuingeducationclassesfortechnicianswhowanttolearnmoreabout

ourproducts.Formoreinformation,contactyourlocaldealerorClubCar’sTechnicalServicesdepartmentfora

listofupcomingclasses.

Thismanualcoversallaspectsoftypicalvehicleservice;uniquesituations,however,dosometimesoccurwhen

servicingavehicle.Ifitappearsthataservicequestionisnotansweredinthismanual,youmaywritetousat:Club

Car,Inc.;P .O.Box204658;Augusta,Georgia30917;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.

ClubCar,Carryall,andArmorFlex

areregisteredtrademarksofClubCar,Inc.

ThismanualeffectiveAugust1,2007

2008ElectricPrecedentMaintenanceandServiceManualPagei

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.....................................................................................................4-2

Gouges,Punctures,Tears,LargeScratches,andAbrasions.........................................................................4-3

FrontBody....................................................................................................................................................4-3

FrontBodyRemoval..................................................................................................................................4-3

FrontBodyInstallation...............................................................................................................................4-3

FrontBumper................................................................................................................................................4-5

InstrumentPanel...........................................................................................................................................4-5

InstrumentPanelRemoval–EarlyModelYear............................................................................................4-5

InstrumentPanelInstallation–EarlyModelYear.........................................................................................4-6

InstrumentPanelRemoval–LateModelYear.............................................................................................4-6

InstrumentPanelInstallation–LateModelYear...........................................................................................4-7

FloorMatandRetainers.................................................................................................................................4-8

FloorMatRetainerRemoval.......................................................................................................................4-8

FloorMatRetainerInstallation....................................................................................................................4-8

KickPlateandChargerReceptacleBezel.......................................................................................................4-9

KickPlateandChargerReceptacleBezelRemoval.....................................................................................4-9

KickPlateandChargerReceptacleBezelInstallation...................................................................................4-9

RearBody–Two-PassengerVehicles...........................................................................................................4-10

UniversalAccessoryMounting..................................................................................................................4-10

BackrestandStructuralAccessoryModule(SAM).....................................................................................4-10

RearBodyComponents(Two-Passenger)..................................................................................................4-11

RearBody–Four-PassengerVehicles..........................................................................................................4-14

SeatBacks..............................................................................................................................................4-14

SeatSupport...........................................................................................................................................4-14

FootDeck...............................................................................................................................................4-15

RearBodyComponents(Four-Passenger)................................................................................................4-16

Canopy–Two-Passenger............................................................................................................................4-17

Two-PassengerCanopyRemoval.............................................................................................................4-17

Two-PassengerCanopyInstallation..........................................................................................................4-19

Canopy–Four-Passenger...........................................................................................................................4-19

Four-PassengerCanopyRemoval............................................................................................................4-19

Four-PassengerCanopyInstallation.........................................................................................................4-20

SECTION5—ACCELERATORANDBRAKEPEDALGROUP..........................................................................5-1

PedalGroup..................................................................................................................................................5-1

PedalGroupRemoval................................................................................................................................5-1

MCOR......................................................................................................................................................5-3

2008ElectricPrecedentMaintenanceandServiceManualPageiii

DebrisShields...........................................................................................................................................5-3

BrakeReturnSpring..................................................................................................................................5-3

PawlAssembly..........................................................................................................................................5-3

AcceleratorReturnSpring..........................................................................................................................5-4

PedalGroupInstallation.............................................................................................................................5-6

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

Pageiv2008ElectricPrecedentMaintenanceandServiceManual

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......................................................................................................................10-5

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)........................................................................................................11-38

UsingtheCDMtoRetrieveDatafromtheOnboardComputer...................................................................11-39

CDMTroubleshootingGuide.......................................................................................................................11-39

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)........................................................................................................12-38

UsingtheCDMtoRetrieveDatafromtheOnboardComputer...................................................................12-39

CDMTroubleshootingGuide.......................................................................................................................12-39

SECTION13—IQDISPLAYMODULE(IQDM)ANDIQDM-PDIAGNOSTICS:IQSYSTEM...............................13-1

PluggingtheHandsetintotheVehicle...........................................................................................................13-1

IntroductoryDisplay.....................................................................................................................................13-2

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

2008ElectricPrecedentMaintenanceandServiceManualPagev

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.....................................................................................................................................13-16

Program.................................................................................................................................................13-16

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.....................................................................................................................................................14-3

Functions................................................................................................................................................14-4

Information..............................................................................................................................................14-4

ProgrammerSetup..................................................................................................................................14-4

MonitorMenu..............................................................................................................................................14-4

Speed.....................................................................................................................................................14-4

Throttle...................................................................................................................................................14-5

Pagevi2008ElectricPrecedentMaintenanceandServiceManual

BattAuxVoltage......................................................................................................................................14-5

Temperature............................................................................................................................................14-5

ArmCurrent............................................................................................................................................14-5

FieldCurrent...........................................................................................................................................14-5

ArmaturePWM........................................................................................................................................14-5

FieldPWM..............................................................................................................................................14-5

BrakeVoltsIn..........................................................................................................................................14-5

SpeedPulses..........................................................................................................................................14-6

FootInput...............................................................................................................................................14-6

KeyInput................................................................................................................................................14-6

ForwardInput..........................................................................................................................................14-6

ReverseInput..........................................................................................................................................14-6

ChargerInhibit.........................................................................................................................................14-6

MainContDriver.....................................................................................................................................14-6

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.....................................................................................................................................14-16

Program.................................................................................................................................................14-16

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

2008ElectricPrecedentMaintenanceandServiceManualPagevii

BatteryWarningLightRemoval................................................................................................................15-2

BatteryWarningLightInstallation..............................................................................................................15-3

Forward/ReverseRockerSwitch...................................................................................................................15-3

TestingtheForward/ReverseRockerSwitch..............................................................................................15-3

Forward/ReverseRockerSwitchRemoval.................................................................................................15-3

Forward/ReverseRockerSwitchInstallation..............................................................................................15-4

ElectronicsModuleCover–StyleABatteryConguration..............................................................................15-5

ElectronicsModuleCoverRemoval..........................................................................................................15-5

ElectronicsModuleCoverInstallation........................................................................................................15-5

ElectronicsModuleCover–StyleBandCBatteryCongurations...................................................................15-6

ElectronicsModuleCoverRemoval..........................................................................................................15-6

ElectronicsModuleCoverInstallation........................................................................................................15-6

Tow/RunSwitch–StyleABatteryConguration............................................................................................15-7

TestingtheTow/RunSwitch......................................................................................................................15-7

Tow/RunSwitchRemoval.........................................................................................................................15-7

Tow/RunSwitchInstallation......................................................................................................................15-8

Tow/RunSwitch–StyleBandCBatteryCongurations.................................................................................15-8

TestingtheTow/RunSwitch......................................................................................................................15-8

Tow/RunSwitchRemoval.........................................................................................................................15-8

Tow/RunSwitchInstallation......................................................................................................................15-9

MotorControllerOutputRegulator(MCOR)...................................................................................................15-9

TestingtheMCOR...................................................................................................................................15-9

MCORRemoval......................................................................................................................................15-9

MCORInstallation..................................................................................................................................15-10

ReverseBuzzer..........................................................................................................................................15-10

TestingtheReverseBuzzer.....................................................................................................................15-10

ReverseBuzzerRemoval........................................................................................................................15-10

ReverseBuzzerInstallation.....................................................................................................................15-11

ElectronicsModule–StyleABatteryConguration.......................................................................................15-11

ElectronicsModuleRemoval...................................................................................................................15-11

ElectronicsModuleInstallation................................................................................................................15-12

ElectronicsModule–StyleBandCBatteryCongurations...........................................................................15-14

ElectronicsModuleRemoval...................................................................................................................15-14

ElectronicsModuleInstallation................................................................................................................15-14

SpeedController–StyleABatteryConguration..........................................................................................15-17

TestingtheSolidStateSpeedController..................................................................................................15-17

SpeedControllerRemoval......................................................................................................................15-17

SpeedControllerInstallation....................................................................................................................15-17

SpeedController–StyleBandCBatteryCongurations...............................................................................15-18

TestingtheSolidStateSpeedController..................................................................................................15-18

SpeedControllerRemoval......................................................................................................................15-18

SpeedControllerInstallation....................................................................................................................15-18

Solenoid–StyleABatteryConguration......................................................................................................15-19

TestingtheSolenoid...............................................................................................................................15-19

SolenoidRemoval..................................................................................................................................15-19

SolenoidInstallation................................................................................................................................15-19

Solenoid–StyleBandCBatteryCongurations...........................................................................................15-20

TestingtheSolenoid...............................................................................................................................15-20

SolenoidRemoval..................................................................................................................................15-20

SolenoidInstallation................................................................................................................................15-20

OnboardComputer(OBC)–StyleABatteryConguration............................................................................15-21

TestingtheOnboardComputer................................................................................................................15-21

OnboardComputerRemoval...................................................................................................................15-21

OnboardComputerInstallation................................................................................................................15-21

OnboardComputer(OBC)–StyleBandCBatteryCongurations.................................................................15-22

TestingtheOnboardComputer................................................................................................................15-22

OnboardComputerRemoval...................................................................................................................15-22

OnboardComputerInstallation................................................................................................................15-22

ChargerReceptacle....................................................................................................................................15-23

TestingtheChargerReceptacle...............................................................................................................15-23

ChargerReceptacleInspection................................................................................................................15-23

ChargerReceptacleRemoval..................................................................................................................15-23

ChargerReceptacleInstallation...............................................................................................................15-24

HeadlightAdjustment..................................................................................................................................15-25

Pageviii2008ElectricPrecedentMaintenanceandServiceManual

AimingtheHeadlightBeam.....................................................................................................................15-25

FerriteBeads–CEMarkVehicles...............................................................................................................15-26

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

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(MODEL5BC59JBS6390).........................................................................................18-1

GeneralInformation.....................................................................................................................................18-1

MotorIdentication......................................................................................................................................18-1

ExternalMotorTesting.................................................................................................................................18-1

Motor..........................................................................................................................................................18-3

MotorRemoval........................................................................................................................................18-3

MotorComponentTestingandInspection......................................................................................................18-5

Armature.................................................................................................................................................18-5

FieldWindingsInspection.........................................................................................................................18-6

MotorComponents..................................................................................................................................18-6

BearingInspection...................................................................................................................................18-7

BearingRemoval.....................................................................................................................................18-9

BearingInstallation..................................................................................................................................18-9

SpeedSensorMagnetInspection.............................................................................................................18-9

SpeedSensorMagnetRemoval...............................................................................................................18-9

SpeedSensorMagnetInstallation............................................................................................................18-9

ReconditioningtheMotor.............................................................................................................................18-9

MotorSpecications...............................................................................................................................18-10

2008ElectricPrecedentMaintenanceandServiceManualPageix

MotorAssembly..........................................................................................................................................18-10

MotorInstallation........................................................................................................................................18-12

MotorSpeedSensor...................................................................................................................................18-16

TestingtheMotorSpeedSensor..............................................................................................................18-16

MotorSpeedSensorRemoval.................................................................................................................18-16

MotorSpeedSensorInstallation..............................................................................................................18-16

SECTION19—MOTOR(MODELEJ4-4001)...................................................................................................19-1

GeneralInformation.....................................................................................................................................19-1

MotorIdentication......................................................................................................................................19-1

ExternalMotorTesting.................................................................................................................................19-1

Motor..........................................................................................................................................................19-2

MotorRemoval........................................................................................................................................19-2

MotorDisassembly..................................................................................................................................19-4

MotorComponentTestingandInspection......................................................................................................19-6

ArmatureInspectionandTesting...............................................................................................................19-6

MotorFrameandFieldWindingsInspection..............................................................................................19-8

MotorBrush,Spring,andTerminalInsulatorInspection..............................................................................19-8

ReconditioningtheMotor............................................................................................................................19-11

MotorSpecications...............................................................................................................................19-11

MotorAssembly..........................................................................................................................................19-11

MotorInstallation........................................................................................................................................19-13

SECTION20—TRANSAXLE(TYPEG)..........................................................................................................20-1

Lubrication..................................................................................................................................................20-1

AxleBearingandShaft................................................................................................................................20-1

AxleShaft...............................................................................................................................................20-1

AxleBearing............................................................................................................................................20-4

Transaxle....................................................................................................................................................20-5

TransaxleRemoval..................................................................................................................................20-5

TransaxleDisassembly,Inspection,andAssembly.........................................................................................20-8

TransaxleDisassemblyandInspection......................................................................................................20-8

TransaxleAssembly................................................................................................................................20-10

TransaxleInstallation..................................................................................................................................20-11

SECTION21—IQDISPLAYMODULEPROGRAMMER(IQDM-P):IQSYSTEM...............................................21-1

PluggingtheHandsetintotheVehicle...........................................................................................................21-1

ProgramMenu............................................................................................................................................21-1

SpeedSetting..........................................................................................................................................21-2

FastAccel...............................................................................................................................................21-3

PedalUpMode........................................................................................................................................21-3

SpeedCal...............................................................................................................................................21-3

CodeA,CodeB,andCodeC...................................................................................................................21-3

SlowPedalUp.........................................................................................................................................21-3

KSISROEnable......................................................................................................................................21-4

M2MaxSpeed........................................................................................................................................21-4

SECTION22—IQDISPLAYMODULEPROGRAMMER(IQDM-P):EXCELSYSTEM........................................22-1

PluggingtheHandsetintotheVehicle...........................................................................................................22-1

ProgramMenu............................................................................................................................................22-2

SpeedSetting..........................................................................................................................................22-3

FastAccel...............................................................................................................................................22-3

PedalUpMode........................................................................................................................................22-3

SpeedCal...............................................................................................................................................22-3

S3FWDSpeed.......................................................................................................................................22-4

CodeA,CodeB,andCodeC...................................................................................................................22-4

VehicleS/N.............................................................................................................................................22-4

VehicleDecal..........................................................................................................................................22-4

SECTIONi—INDEX

Pagex2008ElectricPrecedentMaintenanceandServiceManual

2008ElectricPrecedentMaintenanceandServiceManualPagexi

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.

2008ElectricPrecedentMaintenanceandServiceManualPage1-1

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,Page

1-3)(Figure1-2,Page1-3)(Figure1-3,Page1-3).

•Afterdisconnectingthebatteries,wait90secondsforthecontrollercapacitorstodischarge.

•Donotleavechildrenunattendedonvehicle.

Page1-22008ElectricPrecedentMaintenanceandServiceManual

SAFETYGeneralWarnings1

RUN

TOW

(+)

(–)

(Viewedfromdriversideofvehicle)

1.PlaceTOW/RUNSwitchinTOWbeforedisconnectingorconnecting

batterycables.

2.Removenegativebatterycable.

3.Removepositivebatterycable.

Connectbatterycablesinreverseorder.

(+)

POS

NEG

POS

NEG

POS

NEG

(–)

(Viewedfromdriversideofvehicle)

1.PlaceTOW/RUNSwitchinTOWbeforedisconnectingorconnecting

batterycables.

2.Removenegativebatterycable.

3.Removepositivebatterycable.

Connectbatterycablesinreverseorder.

Figure1-1BatteryCableRemoval–StyleAElectric

VehicleBatteryConguration

422

Figure1-2BatteryCableRemoval–StyleBElectric

VehicleBatteryConguration

TOW

RUN

(–)

(+)

(Viewedfromdriversideofvehicle)

1.PlaceTOW/RUNSwitchinTOWbeforedisconnectingor

connectingbatterycables.

2.Removenegativebatterycable.

3.Removepositivebatterycable.

Connectbatterycablesinreverseorder.

49A

Figure1-3BatteryCableRemoval–StyleCElectric

VehicleBatteryConguration

2008ElectricPrecedentMaintenanceandServiceManualPage1-3

SECTION2—VEHICLESPECIFICATIONS2

SPECIFICATIONS

TWO-PAS-

SENGER

ELECTRIC

VEHICLE

FOUR-PAS-

SENGER

ELECTRIC

VEHICLE

POWERSOURCE

Drivemotor:Directdrive,48voltsDC,shunt-wound,3.2hp••

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••

Bodynish:High-glossmolded-incolor••

Tires:18x8.5–8tubeless,4plyrated••

DIMENSIONS/WEIGHT

Overalllength91.5in.(232

cm)

104in.(264

cm)

Overallwidth47.25in.(120

cm)

47.25in.(120

cm)

Overallheight(withcanopy)68.5in.(174

cm)

71in.(180

cm)

Overallheight(atsteeringwheel)48.0in.(122

cm)

48.0in.(122

cm)

Wheelbase65.5in.(166

cm)

65.5in.(166

cm)

Groundclearance4.5in.(11cm)4.5in.(11cm)

Frontwheeltread34.5in.(88

cm)

34.5in.(88

cm)

Rearwheeltread38.6in.(98

cm)

38.6in.(98

cm)

Weight(standardelectricvehiclewithcanopy,withbatteries)855lb.(388

kg)

970lb.(440

kg)

TopSpeedRange5-19mph(8-30.6km/h)

TABLECONTINUEDONNEXTPAGE

2008ElectricPrecedentMaintenanceandServiceManualPage2-1

2GeneralWarningsVEHICLESPECIFICATIONS

SPECIFICATIONS

TWO-PAS-

SENGER

ELECTRIC

VEHICLE

FOUR-PAS-

SENGER

ELECTRIC

VEHICLE

Curbclearancecircle(diameter)17ft-4in.

(528cm)

17ft-4in.

(528cm)

Standardseatingcapacity24

LIQUIDCAPACITIES

Transaxle22oz.(.67

liters)

22oz.(.67

liters)

TIREPRESSURE

Frontandrear

18-20psi

(1.24-1.38

bars)

18-20psi

(1.24-1.38

bars)

Page2-22008ElectricPrecedentMaintenanceandServiceManual

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