Club car Precedent 2014 Manual

2014Precedent®GolfCar

Maintenanceand

ServiceManual

ElectricVehiclewithPowerDrive™BatteryCharger

GasolineVehiclewithKawasakiFE350Engine

ElectricVehiclewithERICChargingSystem

ManualNumber105062901

EditionCode0713A00000

FOREWORD

ClubCarvehiclesaredesignedandbuilttoprovidetheultimateinperformanceefciency;however,proper

maintenanceandrepairareessentialforachievingmaximumservicelifeandcontinuedsafeandreliableoperation.

Thismanualprovidesdetailedinformationforthemaintenanceandrepairof2014Precedentelectricand

gasoline-poweredvehicles,andshouldbethoroughlyreviewedpriortoservicingthevehicle.Theproceduresprovided

hereinmustbeproperlyimplemented,andtheDANGER,WARNING,andCAUTIONstatementsmustbeheeded.

Thismanualwaswrittenforthetrainedtechnicianwhoalreadypossessesknowledgeandskillsinelectricaland

mechanicalrepair.Ifthetechniciandoesnothavesuchknowledgeandskills,attemptedserviceorrepairstothe

vehiclemayrenderthevehicleunsafe.Forthisreason,ClubCaradvisesthatallrepairsand/orservicebeperformed

byanauthorizedClubCardistributor/dealerrepresentativeorbyaClubCarfactory-trainedtechnician.

ItisthepolicyofClubCar,LLCtoassistitsdistributorsanddealersincontinuallyupdatingtheirserviceknowledge

andfacilitiessotheycanprovidepromptandefcientserviceforvehicleowners.Regionaltechnicalrepresentatives,

periodicservicebulletins,maintenanceandservicemanuals,andotherservicepublicationsalsorepresentClubCar’s

continuingcommitmenttocustomersupport.

ClubCaroffersafulllineoftrainingandcontinuingeducationclassesfortechnicianswhowanttolearnmoreabout

ourproducts.Formoreinformation,contactyourlocaldealerorClubCar’sTechnicalServicesdepartmentfora

listofupcomingclasses.

Thismanualcoversallaspectsoftypicalvehicleservice;however,uniquesituationssometimesoccurwhenservicinga

vehicle.Ifitappearsthataservicequestionisnotansweredinthismanual,pleasecontactyournearestauthorized

ClubCardealerordistributorforassistance.Y oumayalsowritetousat:ClubCar,LLC,P .O.Box204658;Augusta,

GA30917–4658USA,Attention:TechnicalServices.

WARNING

•ReadSeeSection1–Safety.beforeattemptinganyserviceonthevehicle.

•Beforeservicingvehicle,readcompletesection(s)andanyreferencedinformationthatmaybe

relevanttotheserviceorrepairtobeperformed.

NOTE:Thismanualrepresentsthemostcurrentinformationatthetimeofpublication.ClubCar,LLCiscontinually

workingtofurtherimproveitsvehiclesandotherproducts.Theseimprovementsmayaffectservicing

procedures.Anymodicationand/orsignicantchangeinspecicationsorprocedureswillbeforwardedtoall

ClubCardealersandwill,whenapplicable,appearinfutureeditionsofthismanual.

ClubCar,LLCreservestherighttochangespecicationsanddesignsatanytimewithoutnoticeandwithout

theobligationofmakingchangestounitspreviouslysold.

Therearenowarrantiesexpressedorimpliedinthismanual.Seethelimitedwarrantyfoundinthevehicle

owner’smanualorwritetoClubCar,LLC,P .O.BOX204658,Augusta,Georgia30917-4658USA,Attention:

WarrantyDepartment.

ClubCar,Carryall,andArmorFlex

areregisteredtrademarksofClubCar,LLC

ThismanualeffectiveJuly15,2013

2014Precedent®GolfCarMaintenanceandServiceManualPagei

CONTENTS

SECTION1–SAFETY......................................................................................................................................1-1

SafetyDetails................................................................................................................................................1-1

PersonalSafety.........................................................................................................................................1-1

MachineSafety..........................................................................................................................................1-1

Information................................................................................................................................................1-1

GeneralWarnings..........................................................................................................................................1-2

DisablingtheVehicle..................................................................................................................................1-3

DisconnectingtheBattery–GasolineVehicles............................................................................................1-3

ConnectingtheBattery–GasolineVehicles................................................................................................1-4

DisconnectingtheBatteries–ElectricVehicles............................................................................................1-4

ConnectingtheBatteries–ElectricVehicles................................................................................................1-4

RecyclingLead-AcidBatteries....................................................................................................................1-5

InternationalSafetySymbolsonBatteries...................................................................................................1-5

SECTION2–VEHICLESPECIFICATIONS........................................................................................................2-1

VehicleSpecications....................................................................................................................................2-1

ChargerSpecications..................................................................................................................................2-3

SECTION3–GENERALINFORMATION...........................................................................................................3-1

ModelIdentication........................................................................................................................................3-1

SafetyCommittee..........................................................................................................................................3-2

Storage–ElectricVehiclewithERICBatteryCharger......................................................................................3-3

PreparingtheElectricVehicleforExtendedStorage.....................................................................................3-3

ReturningtheStoredElectricVehicletoService..........................................................................................3-4

Storage–ElectricVehiclewithPowerDriveBatteryCharger.............................................................................3-5

PreparingtheElectricVehicleforExtendedStorage.....................................................................................3-5

ReturningtheStoredElectricVehicletoService..........................................................................................3-6

Storage–GasolineVehicle............................................................................................................................3-7

PreparingtheGasolineVehicleforExtendedStorage.................................................................................3-7

ReturningtheStoredGasolineVehicletoService........................................................................................3-8

FuelingInstructions–GasolineVehicles.........................................................................................................3-9

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

HeadlightAdjustment.....................................................................................................................................4-6

AimingtheHeadlightBeam........................................................................................................................4-6

InstrumentPanel...........................................................................................................................................4-7

InstrumentPanelRemoval.........................................................................................................................4-7

InstrumentPanelInstallation......................................................................................................................4-7

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

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

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

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

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

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

KickPlateandChokeButtonBezel...............................................................................................................4-10

2014Precedent®GolfCarMaintenanceandServiceManualPageiii

KickPlateandChokeButtonRemoval......................................................................................................4-10

KickPlateandChokeButtonInstallation...................................................................................................4-10

SeatBottom.................................................................................................................................................4-11

RearBody–Two-PassengerVehicles...........................................................................................................4-12

UniversalAccessoryMounting..................................................................................................................4-12

SeatBackandStructuralAccessoryModule(SAM)...................................................................................4-12

RearBodyComponents(Two-Passenger).................................................................................................4-14

RearBody–Four-PassengerVehicles..........................................................................................................4-16

SeatBacks..............................................................................................................................................4-16

SeatSupport...........................................................................................................................................4-17

FootDeck...............................................................................................................................................4-18

RearBodyComponents(Four-Passenger)................................................................................................4-18

Canopy–Two-Passenger............................................................................................................................4-19

Two-PassengerCanopyRemoval.............................................................................................................4-19

Two-PassengerCanopyInstallation..........................................................................................................4-21

Canopy–Four-Passenger...........................................................................................................................4-22

Four-PassengerCanopyRemoval............................................................................................................4-22

Four-PassengerCanopyInstallation.........................................................................................................4-22

Canopy(MonsoonVersion)–Four-Passenger...............................................................................................4-24

MonsoonCanopyRemoval......................................................................................................................4-24

MonsoonCanopyInstallation....................................................................................................................4-24

SECTION5–ACCELERATORANDBRAKEPEDALGROUP............................................................................5-1

PedalGroup–ElectricVehicle.......................................................................................................................5-1

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

MCOR3....................................................................................................................................................5-2

PedalGroupInstallation.............................................................................................................................5-3

PedalGroup–GasolineVehicle.....................................................................................................................5-4

PedalGroupRemoval................................................................................................................................5-4

ThrottlePositionSensor.............................................................................................................................5-5

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

DebrisShields...............................................................................................................................................5-6

AcceleratorPedalRemoval............................................................................................................................5-6

AcceleratorPedalInstallation.........................................................................................................................5-6

BrakePedalRemoval....................................................................................................................................5-7

BrakePedalInstallation.................................................................................................................................5-7

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

RackandPinionInspection........................................................................................................................7-4

RackandPinionRemoval..........................................................................................................................7-5

Pageiv2014Precedent®GolfCarMaintenanceandServiceManual

RackandPinionInstallation.......................................................................................................................7-5

FrontSuspension..........................................................................................................................................7-6

Lubrication................................................................................................................................................7-6

WheelAlignment.......................................................................................................................................7-6

FrontSuspensionComponents.......................................................................................................................7-8

TieRodEndRemoval................................................................................................................................7-8

TieRodInstallation....................................................................................................................................7-8

LeafSpringRemoval.................................................................................................................................7-9

LeafSpringInstallation...............................................................................................................................7-9

KingpinandSteeringSpindleRemoval.......................................................................................................7-9

KingpinandSteeringSpindleInstallation...................................................................................................7-10

ControlArmRemoval...............................................................................................................................7-10

ControlArmInstallation.............................................................................................................................7-11

ShockAbsorberRemoval..........................................................................................................................7-11

ShockAbsorberInstallation.......................................................................................................................7-11

FrontWheelBearingsandHubs...................................................................................................................7-14

FrontWheelFreePlayInspection.............................................................................................................7-14

FrontHubRemoval..................................................................................................................................7-14

HubInstallation........................................................................................................................................7-14

SECTION8–WHEELSANDTIRES..................................................................................................................8-1

GeneralInformation.......................................................................................................................................8-1

Wheels.........................................................................................................................................................8-1

WheelRemoval.........................................................................................................................................8-1

WheelInstallation......................................................................................................................................8-1

Tires.............................................................................................................................................................8-2

TireRemoval.............................................................................................................................................8-2

TireRepair................................................................................................................................................8-3

TireInstallation..........................................................................................................................................8-3

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).........................................................................................................9-5

LeafSpringRemoval(Four-PassengerVehicles).........................................................................................9-5

LeafSpringInstallation(Four-PassengerVehicles)......................................................................................9-7

SECTION10–PERIODICMAINTENANCE......................................................................................................10-1

GeneralInformation.....................................................................................................................................10-1

Pre-OperationandDailySafetyChecklist......................................................................................................10-1

..............................................................................................................................................................10-1

PerformanceInspection...........................................................................................................................10-2

Maintenance...............................................................................................................................................10-3

PeriodicServiceSchedules..........................................................................................................................10-4

PeriodicLubricationSchedules.....................................................................................................................10-7

EngineOil–GasolineVehicles.....................................................................................................................10-9

EngineOilLevelCheck............................................................................................................................10-9

EngineOilAndFilterChange...................................................................................................................10-9

OilViscosity...........................................................................................................................................10-11

SECTION11–IQDISPLAYMODULE(IQDM)ANDIQDM-PDIAGNOSTICS:EXCELSYSTEMWITH

POWERDRIVECHARGER...............................................................................................................................11-1

PluggingtheHandsetintotheVehicle............................................................................................................11-1

QuickReferenceGuide–ExcelwithPowerDriveCharger...............................................................................11-2

IntroductoryDisplay......................................................................................................................................11-2

2014Precedent®GolfCarMaintenanceandServiceManualPagev

MenuNavigation..........................................................................................................................................11-3

Program(IQDM-Ponly)............................................................................................................................11-4

Monitor....................................................................................................................................................11-4

Faults......................................................................................................................................................11-4

Functions.................................................................................................................................................11-4

Information...............................................................................................................................................11-4

ProgrammerSetup...................................................................................................................................11-4

MonitorMenu...............................................................................................................................................11-5

Speed......................................................................................................................................................11-5

Throttle....................................................................................................................................................11-5

BattAuxVoltage.......................................................................................................................................11-5

Temperature.............................................................................................................................................11-5

ArmCurrent.............................................................................................................................................11-6

FieldCurrent............................................................................................................................................11-6

ArmaturePWM.........................................................................................................................................11-6

FieldPWM...............................................................................................................................................11-6

BrakeVoltsIn...........................................................................................................................................11-6

SpeedPulses...........................................................................................................................................11-6

FootInput................................................................................................................................................11-6

KeyInput.................................................................................................................................................11-6

ForwardInput...........................................................................................................................................11-7

ReverseInput...........................................................................................................................................11-7

ChargerInhibit..........................................................................................................................................11-7

MainContDriver......................................................................................................................................11-7

PasswordTries(IQDM-POnly)..................................................................................................................11-7

Odometer.................................................................................................................................................11-7

VehicleSpeeds(IQDM-POnly)..................................................................................................................11-7

PedalCounters.........................................................................................................................................11-8

FaultCounters..........................................................................................................................................11-8

FaultCountOdometers.............................................................................................................................11-8

NegIA250...............................................................................................................................................11-8

NegIA300...............................................................................................................................................11-8

FaultsMenu.................................................................................................................................................11-9

SystemFaults..........................................................................................................................................11-9

HWFailsafe...........................................................................................................................................11-11

ThrottleFault..........................................................................................................................................11-11

Speedsensor.........................................................................................................................................11-12

MainWelded..........................................................................................................................................11-12

MainDriverOn.......................................................................................................................................11-12

MainDriverOff.......................................................................................................................................11-12

MainCoilOpen.......................................................................................................................................11-12

FLD(Field)Missing.................................................................................................................................11-13

HPD......................................................................................................................................................11-13

Overvoltage............................................................................................................................................11-13

LowBatteryVoltage(Undervoltage).........................................................................................................11-13

ThermalCutback....................................................................................................................................11-13

MotorStall..............................................................................................................................................11-14

MainDropout(1or2)..............................................................................................................................11-14

CurrentSenseFault................................................................................................................................11-14

IncorrectPassword(IQDM-Ponly)...........................................................................................................11-14

MaxPasswordTries(IQDM-Ponly).........................................................................................................11-14

M–Shorted............................................................................................................................................11-15

FaultHistory...........................................................................................................................................11-15

ClearingFaultHistory.............................................................................................................................11-15

FunctionsMenu..........................................................................................................................................11-15

GetSettingsFromController...................................................................................................................11-15

WriteSettingstoController......................................................................................................................11-16

ResetAllSettings...................................................................................................................................11-18

Information.................................................................................................................................................11-18

ModelNumber........................................................................................................................................11-18

SerialNumber........................................................................................................................................11-18

MFGDate..............................................................................................................................................11-18

SoftwareVersion....................................................................................................................................11-18

ProgrammerSetup.....................................................................................................................................11-19

Pagevi2014Precedent®GolfCarMaintenanceandServiceManual

Program.................................................................................................................................................11-19

Faults....................................................................................................................................................11-19

Information.............................................................................................................................................11-19

IQDMandIQDM-PHandsetTroubleshooting...............................................................................................11-20

TestProcedures.........................................................................................................................................11-21

SECTION12–IQDISPLAYMODULEPROGRAMMER(IQDM-P):EXCELSYSTEMWITHPOWERDRIVE

CHARGER......................................................................................................................................................12-1

PluggingtheHandsetintotheVehicle...........................................................................................................12-1

ProgramMenu............................................................................................................................................12-2

SpeedSetting..........................................................................................................................................12-3

FastAccel...............................................................................................................................................12-3

PedalUpMode........................................................................................................................................12-3

SpeedCal...............................................................................................................................................12-3

S3FWDSpeed.......................................................................................................................................12-4

CodeA,CodeB,andCodeC...................................................................................................................12-4

VehicleS/N.............................................................................................................................................12-4

VehicleDecal..........................................................................................................................................12-4

SECTION13–EXCELSYSTEMTROUBLESHOOTING:WITHPOWERDRIVECHARGER...............................13-1

GeneralInformation.....................................................................................................................................13-1

AttributesoftheExcelSystem..................................................................................................................13-1

Features.................................................................................................................................................13-2

WiringDiagrams..........................................................................................................................................13-3

Troubleshooting...........................................................................................................................................13-8

TroubleshootingtheVehiclewiththeIQDM...............................................................................................13-8

TroubleshootingGuide1..........................................................................................................................13-8

TroubleshootingGuide2.........................................................................................................................13-11

TestProcedures.........................................................................................................................................13-13

BatteryWarningLight..................................................................................................................................13-37

CommunicationDisplayModule(CDM)........................................................................................................13-38

UsingtheCDMtoRetrieveDatafromtheOnboardComputer...................................................................13-39

CDMTroubleshootingGuide.......................................................................................................................13-40

SECTION14–ELECTRICALCOMPONENTS:ELECTRICVEHICLEWITHPOWERDRIVE

CHARGER......................................................................................................................................................14-1

KeySwitch..................................................................................................................................................14-1

TestingtheKeySwitch.............................................................................................................................14-1

KeySwitchRemoval................................................................................................................................14-1

KeySwitchInstallation.............................................................................................................................14-1

BatteryWarningLight...................................................................................................................................14-2

TestingtheBatteryWarningLight..............................................................................................................14-2

BatteryWarningLightRemoval................................................................................................................14-2

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

Forward/ReverseRockerSwitch...................................................................................................................14-3

TestingtheForward/ReverseRockerSwitch..............................................................................................14-3

Forward/ReverseRockerSwitchRemoval.................................................................................................14-3

Forward/ReverseRockerSwitchInstallation..............................................................................................14-4

ElectronicsModuleCover.............................................................................................................................14-5

ElectronicsModuleCoverRemoval..........................................................................................................14-5

ElectronicsModuleCoverInstallation........................................................................................................14-5

Tow/RunSwitch...........................................................................................................................................14-6

TestingtheT ow/RunSwitch......................................................................................................................14-6

Tow/RunSwitchRemoval.........................................................................................................................14-6

Tow/RunSwitchInstallation......................................................................................................................14-6

MotorControllerOutputRegulator3(MCOR3)..............................................................................................14-7

TestingtheMCOR3.................................................................................................................................14-7

MCOR3Removal....................................................................................................................................14-7

MCOR3Installation..................................................................................................................................14-7

ReverseBuzzer...........................................................................................................................................14-8

TestingtheReverseBuzzer......................................................................................................................14-8

2014Precedent®GolfCarMaintenanceandServiceManualPagevii

ReverseBuzzerRemoval.........................................................................................................................14-8

ReverseBuzzerInstallation......................................................................................................................14-8

ElectronicsModule......................................................................................................................................14-9

ElectronicsModuleRemoval....................................................................................................................14-9

ElectronicsModuleInstallation................................................................................................................14-10

SpeedController........................................................................................................................................14-12

TestingtheSolidStateSpeedController..................................................................................................14-12

SpeedControllerRemoval......................................................................................................................14-12

SpeedControllerInstallation....................................................................................................................14-12

Solenoid.....................................................................................................................................................14-13

TestingtheSolenoid...............................................................................................................................14-13

SolenoidRemoval..................................................................................................................................14-13

SolenoidInstallation................................................................................................................................14-13

OnboardComputer(OBC)...........................................................................................................................14-14

TestingtheOnboardComputer................................................................................................................14-14

OnboardComputerRemoval...................................................................................................................14-14

OnboardComputerInstallation................................................................................................................14-14

ChargerReceptacle....................................................................................................................................14-15

TestingtheChargerReceptacle...............................................................................................................14-15

ChargerReceptacleInspection................................................................................................................14-15

ChargerReceptacleRemoval..................................................................................................................14-15

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

SECTION15–BATTERIES:ELECTRICVEHICLEWITHPOWERDRIVECHARGER........................................15-1

GeneralInformation.....................................................................................................................................15-1

BatteryTestingBasics–8Volt......................................................................................................................15-2

Observation.............................................................................................................................................15-2

MeasuringVoltageofBatterySet..............................................................................................................15-2

MeasuringVoltageofanIndividualBattery................................................................................................15-2

BatteryCellNumbering............................................................................................................................15-2

BatteryTesting–8Volt................................................................................................................................15-3

FullyChargeBatteriesTest......................................................................................................................15-3

HydrometerTest......................................................................................................................................15-3

DischargeTest........................................................................................................................................15-6

BatteryRegrouping......................................................................................................................................15-7

BatteryReplacement...................................................................................................................................15-9

BatteryCare................................................................................................................................................15-9

WaterQuality..........................................................................................................................................15-9

BatteryCare–VehiclesEquippedwiththeSingle-PointWateringSystem..................................................15-11

BatteryCare–VehiclesWithouttheSingle-PointWateringSystem............................................................15-12

Self-Discharge........................................................................................................................................15-13

ElectrolyteLevel.....................................................................................................................................15-13

VibrationDamage...................................................................................................................................15-13

SinglePointWateringSystem(SPWS).........................................................................................................15-14

InitialMaintenanceoftheSPWS..............................................................................................................15-14

WateringBatterieswiththeSPWS...........................................................................................................15-14

PowerDriveBatteryCharger(Ferroresonant)................................................................................................15-16

ChargingBatteries..................................................................................................................................15-18

PlugandReceptacle...............................................................................................................................15-19

ChargerShutsOffAfter16Hours............................................................................................................15-19

Deep-Discharge.....................................................................................................................................15-19

EarlyExcessiveDischarging...................................................................................................................15-20

IncomingACService..............................................................................................................................15-20

FleetRotation.........................................................................................................................................15-20

NumberingVehiclesandChargers...........................................................................................................15-20

BatteryStorage..........................................................................................................................................15-20

ChargingaBatteryPackthathasLowVoltage.............................................................................................15-20

Pageviii2014Precedent®GolfCarMaintenanceandServiceManual

SECTION16–BATTERYCHARGER:POWERDRIVE......................................................................................16-1

SECTION17–MOTOR(MODELEJ8-4001A):ELECTRICVEHICLE................................................................17-1

GeneralInformation.....................................................................................................................................17-1

ExternalMotorTesting.................................................................................................................................17-1

Motor..........................................................................................................................................................17-4

MotorRemoval........................................................................................................................................17-4

MotorDisassembly..................................................................................................................................17-5

MotorComponentTestingandInspection......................................................................................................17-8

ArmatureInspectionandTesting...............................................................................................................17-8

MotorFrameandFieldWindingsInspection.............................................................................................17-10

MotorBrush,Spring,andTerminalInsulatorInspection.............................................................................17-10

ReconditioningtheMotor............................................................................................................................17-13

MotorSpecications...............................................................................................................................17-13

MotorAssembly..........................................................................................................................................17-13

MotorInstallation........................................................................................................................................17-15

SECTION18–TRANSAXLE:ELECTRICVEHICLE.........................................................................................18-1

Lubrication..................................................................................................................................................18-1

AxleBearingandShaft................................................................................................................................18-1

AxleShaft...............................................................................................................................................18-1

AxleBearing............................................................................................................................................18-4

TransaxleRemoval......................................................................................................................................18-5

TransaxleDisassembly,Inspection,andAssembly.........................................................................................18-7

TransaxleDisassemblyandInspection......................................................................................................18-7

TransaxleAssembly.................................................................................................................................18-9

TransaxleInstallation..................................................................................................................................18-10

SECTION19–TROUBLESHOOTINGANDELECTRICALSYSTEM(GASOLINEVEHICLE).............................19-1

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

TroubleshootingGuide.................................................................................................................................19-1

WiringDiagrams–ThrottlePositionSensor(TPS).........................................................................................19-6

ElectricalSystem........................................................................................................................................19-11

TestProcedures.........................................................................................................................................19-11

SECTION20–ELECTRICALCOMPONENTS(GASOLINEVEHICLE)..............................................................20-1

Starter/Generator.........................................................................................................................................20-1

TestingtheStarter/Generator....................................................................................................................20-1

Starter/GeneratorRemoval......................................................................................................................20-1

DisassemblyoftheStarter/GeneratortoServicetheBrushes.....................................................................20-2

BrushInspectionandReplacement...........................................................................................................20-2

BrushSpringInspectionandReplacement................................................................................................20-3

Starter/GeneratorAssembly.....................................................................................................................20-4

DisassemblyoftheStarter/GeneratortoServicetheArmature/Commutator................................................20-4

BearingCleaningandInspection..............................................................................................................20-5

BearingRemoval.....................................................................................................................................20-6

FieldCoilAssembly.................................................................................................................................20-6

VisualInspectionofArmature...................................................................................................................20-6

CommutatorCleaningandInspection.......................................................................................................20-7

ArmatureGroundTest..............................................................................................................................20-8

VisualInspectionofFieldCoils.................................................................................................................20-8

Starter/GeneratorRework........................................................................................................................20-9

Starter/GeneratorAssembly.....................................................................................................................20-9

Starter/GeneratorInstallation...................................................................................................................20-10

BeltTensionAdjustment..........................................................................................................................20-11

VoltageRegulator.......................................................................................................................................20-13

TestingtheVoltageRegulator..................................................................................................................20-13

VoltageRegulatorRemoval.....................................................................................................................20-13

VoltageRegulatorInstallation..................................................................................................................20-13

2014Precedent®GolfCarMaintenanceandServiceManualPageix

KeySwitch.................................................................................................................................................20-14

TestingtheKeySwitch............................................................................................................................20-14

KeySwitchRemoval...............................................................................................................................20-14

KeySwitchInstallation............................................................................................................................20-15

Solenoid.....................................................................................................................................................20-15

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

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

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

Fuse..........................................................................................................................................................20-16

TestingtheFuse.....................................................................................................................................20-16

FuseRemoval........................................................................................................................................20-16

FuseInstallation.....................................................................................................................................20-16

LimitSwitches............................................................................................................................................20-16

AcceleratorPedalLimitSwitch................................................................................................................20-16

KillLimitSwitch......................................................................................................................................20-17

NeutralLockoutLimitSwitch...................................................................................................................20-17

NeutralLockoutCam..................................................................................................................................20-18

TestingtheNeutralLockoutCam.............................................................................................................20-18

NeutralLockoutCamRemoval................................................................................................................20-18

NeutralLockoutCamInstallation.............................................................................................................20-18

ReverseWarningBuzzer.............................................................................................................................20-18

TestingtheReverseWarningBuzzer........................................................................................................20-19

ReverseWarningBuzzerRemoval..........................................................................................................20-19

ReverseWarningBuzzerInstallation........................................................................................................20-19

ReverseBuzzerLimitSwitch.......................................................................................................................20-20

TestingtheReverseBuzzerLimitSwitch..................................................................................................20-20

ReverseBuzzerLimitSwitchRemoval.....................................................................................................20-20

ReverseBuzzerLimitSwitchInstallation..................................................................................................20-20

LowOilWarningLight.................................................................................................................................20-21

TestingtheLowOilWarningLight............................................................................................................20-21

LowOilWarningLightRemoval...............................................................................................................20-21

LowOilWarningLightInstallation............................................................................................................20-21

FuelGauge................................................................................................................................................20-22

TestingtheFuelGauge...........................................................................................................................20-22

FuelGaugeRemoval..............................................................................................................................20-22

FuelGaugeInstallation...........................................................................................................................20-22

FuelLevelSendingUnit..............................................................................................................................20-23

TestingtheFuelLevelSendingUnit.........................................................................................................20-23

HourMeter.................................................................................................................................................20-23

TestingtheHourMeter............................................................................................................................20-23

HourMeterRemoval...............................................................................................................................20-23

HourMeterInstallation............................................................................................................................20-23

IgnitionCoil................................................................................................................................................20-24

IgnitionCoilRemoval..............................................................................................................................20-24

IgnitionCoilInstallation...........................................................................................................................20-25

OilLevelSensor.........................................................................................................................................20-27

TestingtheOilLevelSensor....................................................................................................................20-27

OilLevelSensorRemoval.......................................................................................................................20-27

OilLevelSensorInstallation....................................................................................................................20-27

Battery.......................................................................................................................................................20-27

GeneralInformation................................................................................................................................20-28

Battery–GasolineVehicles.....................................................................................................................20-28

PreventiveMaintenance..........................................................................................................................20-29

Self-Discharge........................................................................................................................................20-30

WaterLevel............................................................................................................................................20-30

VibrationDamage...................................................................................................................................20-30

MineralContent......................................................................................................................................20-30

BatteryRemoval.....................................................................................................................................20-31

ChargingtheBattery...............................................................................................................................20-31

BatteryInstallation..................................................................................................................................20-32

BatteryStorage......................................................................................................................................20-32

ChargingaDeadBattery.........................................................................................................................20-32

GroundCables...........................................................................................................................................20-32

TestingtheGroundCables......................................................................................................................20-33

Pagex2014Precedent®GolfCarMaintenanceandServiceManual

SECTION21–AS26FE350ENGINE..............................................................................................................21-1

GeneralInformation.....................................................................................................................................21-1

BeforeServicing......................................................................................................................................21-1

EngineRotation.......................................................................................................................................21-1

SparkPlug..............................................................................................................................................21-2

CylinderHead.............................................................................................................................................21-3

GeneralInformation.................................................................................................................................21-3

BreatherValve(ReedValve).....................................................................................................................21-3

ValveClearanceCheckandAdjustment....................................................................................................21-3

Crankcase...................................................................................................................................................21-4

EngineRemoval......................................................................................................................................21-4

CrankcaseCoverRemoval.......................................................................................................................21-5

OilLevelSensor......................................................................................................................................21-6

CrankcaseCoverInstallation....................................................................................................................21-7

IgnitionCoilandFlywheel.............................................................................................................................21-8

IgnitionCoilandFlywheelRemoval..........................................................................................................21-8

FlywheelInstallation................................................................................................................................21-9

IgnitionCoilInstallation...........................................................................................................................21-10

CrankcaseCoverInstallation...................................................................................................................21-10

EngineInstallation......................................................................................................................................21-10

TorqueSpecications..................................................................................................................................21-12

AdjustmentsandSettings............................................................................................................................21-12

SECTION22–FUELSYSTEM........................................................................................................................22-1

GeneralInformation.....................................................................................................................................22-1

Carburetor...................................................................................................................................................22-1

MainJetElevation/SizeChart...................................................................................................................22-3

ChangingtheMainJet.............................................................................................................................22-3

EngineControlLinkage................................................................................................................................22-6

GeneralInformation.................................................................................................................................22-6

GroundSpeed.........................................................................................................................................22-6

GovernorCable.......................................................................................................................................22-6

AcceleratorCable....................................................................................................................................22-8

ClosedThrottleorIdleAdjustment............................................................................................................22-8

EngineRPMAdjustment..........................................................................................................................22-9

EngineBackre.......................................................................................................................................22-9

ChokeandAirIntakeSystem......................................................................................................................22-10

GeneralInformation................................................................................................................................22-10

ChokeButton.........................................................................................................................................22-11

AirIntakeComponentsRemoval..............................................................................................................22-12

AirIntakeComponentsInstallation...........................................................................................................22-12

AirFilter.................................................................................................................................................22-12

FuelFilter...................................................................................................................................................22-14

GeneralInformation................................................................................................................................22-14

FuelFilterRemoval.................................................................................................................................22-14

FuelFilterInstallation..............................................................................................................................22-14

FuelPump.................................................................................................................................................22-16

GeneralInformation................................................................................................................................22-16

FuelPumpRemoval...............................................................................................................................22-16

FuelPumpInstallation.............................................................................................................................22-16

FuelTank...................................................................................................................................................22-17

GeneralInformation................................................................................................................................22-17

FuelTankRemoval.................................................................................................................................22-17

FuelTankDisposal.................................................................................................................................22-18

FuelTankStorage..................................................................................................................................22-19

FuelTankInstallation..............................................................................................................................22-19

FuelLines..................................................................................................................................................22-20

FuelShut-OffValve.....................................................................................................................................22-20

FullyOpenPosition.................................................................................................................................22-21

CarbonCanister.........................................................................................................................................22-21

CarbonCanisterRemoval.......................................................................................................................22-21

CarbonCanisterInstallation....................................................................................................................22-22

2014Precedent®GolfCarMaintenanceandServiceManualPagexi

SECTION23–EXHAUSTSYSTEM.................................................................................................................23-1

Mufer........................................................................................................................................................23-1

MuferRemoval......................................................................................................................................23-1

MuferInstallation....................................................................................................................................23-1

SECTION24–UNITIZEDTRANSAXLE(GASOLINEVEHICLE).......................................................................24-1

GeneralInformation.....................................................................................................................................24-1

ShifterLever............................................................................................................................................24-1

NeutralLockout.......................................................................................................................................24-1

GovernorSystem.....................................................................................................................................24-2

UnitizedTransaxleService.......................................................................................................................24-2

ToolsRequiredForThisSection...............................................................................................................24-3

Lubrication..............................................................................................................................................24-3

AxleBearingandShaft–Kawasaki..............................................................................................................24-4

AxleShaftandOilSealRemoval..............................................................................................................24-4

AxleBearing............................................................................................................................................24-5

AxleShaftandOilSealInstallation...........................................................................................................24-7

AxleBearingandShaft–Graziano...............................................................................................................24-8

AxleShaftandOilSealRemoval..............................................................................................................24-8

AxleBearing............................................................................................................................................24-9

AxleShaftandOilSealInstallation...........................................................................................................24-9

UnitizedTransaxleRemoval........................................................................................................................24-10

UnitizedTransaxleInstallation.....................................................................................................................24-18

Forward/ReverseShifterCable....................................................................................................................24-23

Forward/ReverseShifterCableRemoval..................................................................................................24-23

Forward/ReverseShifterCableInstallation...............................................................................................24-23

Forward/ReverseShifterCableAdjustment..............................................................................................24-25

SECTION25–TORQUECONVERTER(GASOLINEVEHICLE)........................................................................25-1

GeneralInformation.....................................................................................................................................25-1

Troubleshooting...........................................................................................................................................25-2

DriveBelt....................................................................................................................................................25-3

DriveBeltRemoval..................................................................................................................................25-3

DriveBeltInstallation...............................................................................................................................25-3

DriveClutch................................................................................................................................................25-4

DriveClutchRemoval..............................................................................................................................25-4

DriveClutchCleaningandInspection........................................................................................................25-6

DriveClutchDisassembly.........................................................................................................................25-8

InspectionofDriveClutchParts...............................................................................................................25-10

DriveClutchAssembly............................................................................................................................25-11

DriveClutchInstallation..........................................................................................................................25-12

DrivenClutch.............................................................................................................................................25-13

DrivenClutchRemoval...........................................................................................................................25-13

DrivenClutchDisassembly......................................................................................................................25-14

DrivenClutchInspection.........................................................................................................................25-14

DrivenClutchAssembly..........................................................................................................................25-15

DrivenClutchInstallation.........................................................................................................................25-17

SECTION26–IQDISPLAYMODULE(IQDM)ANDIQDM-PDIAGNOSTICS:EXCELSYSTEMWITHERIC

CHARGING....................................................................................................................................................26-1

PluggingtheHandsetintotheVehicle...........................................................................................................26-1

QuickReferenceGuide–ExcelwithERICChargingSystem..........................................................................26-2

IntroductoryDisplay.....................................................................................................................................26-3

MenuNavigation.........................................................................................................................................26-4

Program(IQDM-Ponly)...........................................................................................................................26-4

Monitor...................................................................................................................................................26-4

Faults.....................................................................................................................................................26-4

Functions................................................................................................................................................26-4

Information..............................................................................................................................................26-5

ProgrammerSetup..................................................................................................................................26-5

Pagexii2014Precedent®GolfCarMaintenanceandServiceManual

MonitorMenu..............................................................................................................................................26-5

BattVoltage.............................................................................................................................................26-5

BDIPercent.............................................................................................................................................26-5

Speed.....................................................................................................................................................26-6

Throttle...................................................................................................................................................26-6

Temperature............................................................................................................................................26-6

ArmCurrent............................................................................................................................................26-6

FieldCurrent...........................................................................................................................................26-6

ArmaturePWM........................................................................................................................................26-6

FieldPWM..............................................................................................................................................26-6

SpeedPulses..........................................................................................................................................26-6

FootInput...............................................................................................................................................26-7

KeyInput................................................................................................................................................26-7

ForwardInput..........................................................................................................................................26-7

ReverseInput..........................................................................................................................................26-7

ModeSwitchInput...................................................................................................................................26-7

ChargerInhibit.........................................................................................................................................26-7

MainContDriver.....................................................................................................................................26-7

LEDDriver..............................................................................................................................................26-7

PasswordTries(IQDM-POnly).................................................................................................................26-8

Odometer................................................................................................................................................26-8

AmpHoursDisplay..................................................................................................................................26-8

VehicleSpeeds(IQDM-POnly).................................................................................................................26-8

PedalCounters........................................................................................................................................26-8

FaultCounters.........................................................................................................................................26-8

FaultCountOdometers............................................................................................................................26-8

FaultsMenu................................................................................................................................................26-9

SystemFaults.........................................................................................................................................26-9

FaultRecovery.......................................................................................................................................26-11

FaultDescriptions...................................................................................................................................26-12

IncorrectPassword(IQDM-Ponly)...........................................................................................................26-12

MaxPasswordTries(IQDM-Ponly).........................................................................................................26-12

ThrottleFault..........................................................................................................................................26-12

LowBatteryVoltage(Undervoltage).........................................................................................................26-12

Overvoltage............................................................................................................................................26-12

ThermalCutback....................................................................................................................................26-13

Anti-TamperFault...................................................................................................................................26-13

HPD......................................................................................................................................................26-13

MainDrvrOverCurrent............................................................................................................................26-13

LockoutFault.........................................................................................................................................26-13

LowSoC................................................................................................................................................26-13

MainWelded..........................................................................................................................................26-14

HighSpeedWalkAway............................................................................................................................26-14

Speedsensor.........................................................................................................................................26-14

MainDriverOn.......................................................................................................................................26-14

MainCoilOpen.......................................................................................................................................26-14

MainDropout(1or2)..............................................................................................................................26-15

MotorStall..............................................................................................................................................26-15

MainDriverOff.......................................................................................................................................26-15

CurrentSenseFault................................................................................................................................26-15

M–Shorted............................................................................................................................................26-15

FLD(Field)Missing.................................................................................................................................26-15

HWFailsafe...........................................................................................................................................26-16

FaultHistory...........................................................................................................................................26-16

ClearFaultHistory..................................................................................................................................26-16

FunctionsMenu..........................................................................................................................................26-16

GetSettingsFromController...................................................................................................................26-16

WriteSettingstoController......................................................................................................................26-18

ResetAllSettings...................................................................................................................................26-19

Information.................................................................................................................................................26-20

ModelNumber........................................................................................................................................26-20

SerialNumber........................................................................................................................................26-20

SoftwareVersion....................................................................................................................................26-20

HardwareVersion...................................................................................................................................26-20

2014Precedent®GolfCarMaintenanceandServiceManualPagexiii

ParamBlockVersion...............................................................................................................................26-20

MFGDate..............................................................................................................................................26-20

ProgrammerSetup.....................................................................................................................................26-21

Program.................................................................................................................................................26-21

Faults....................................................................................................................................................26-21

Information.............................................................................................................................................26-21

IQDMandIQDM-PHandsetTroubleshooting...............................................................................................26-22

TestProcedures.........................................................................................................................................26-23

SECTION27–IQDISPLAYMODULEPROGRAMMER(IQDM-P):EXCELSYSTEMWITHERIC

CHARGING....................................................................................................................................................27-1

PluggingtheHandsetintotheVehicle...........................................................................................................27-1

ProgramMenu............................................................................................................................................27-2

Settings..................................................................................................................................................27-3

AmpHours..............................................................................................................................................27-5

AccessCodes.........................................................................................................................................27-5

VehicleID...............................................................................................................................................27-5

SECTION28–EXCELSYSTEMTROUBLESHOOTING:WITHERICCHARGING.............................................28-1

GeneralInformation.....................................................................................................................................28-1

Accessories.............................................................................................................................................28-1

ChargeIndicatorLight..............................................................................................................................28-1

AttributesoftheExcelSystem..................................................................................................................28-2

KeyDifferences:ExcelwithERICChargingSystemvs.PowerDriveChargers............................................28-2

Features.................................................................................................................................................28-3

WiringDiagrams..........................................................................................................................................28-4

Troubleshooting..........................................................................................................................................28-11

TroubleshootingtheVehiclewiththeIQDM..............................................................................................28-11

TroubleshootingGuide1.........................................................................................................................28-11

TroubleshootingGuide2.........................................................................................................................28-14

TestProcedures.........................................................................................................................................28-16

TestingBasics........................................................................................................................................28-16

SECTION29–ELECTRICALCOMPONENTS:ELECTRICVEHICLEWITHERICCHARGING..........................29-1

KeySwitch..................................................................................................................................................29-1

TestingtheKeySwitch.............................................................................................................................29-1

KeySwitchRemoval................................................................................................................................29-1

KeySwitchInstallation.............................................................................................................................29-1

ChargeIndicatorLight..................................................................................................................................29-2

TestingtheChargeIndicatorLight.............................................................................................................29-2

ChargeIndicatorLightRemoval................................................................................................................29-2

ChargeIndicatorLightInstallation.............................................................................................................29-3

Forward/ReverseRockerSwitch...................................................................................................................29-3

TestingtheForward/ReverseRockerSwitch..............................................................................................29-3

Forward/ReverseRockerSwitchRemoval.................................................................................................29-3

Forward/ReverseRockerSwitchInstallation..............................................................................................29-4

ElectronicsModuleCover.............................................................................................................................29-5

ElectronicsModuleCoverRemoval..........................................................................................................29-5

ElectronicsModuleCoverInstallation........................................................................................................29-5

Tow/RunSwitch...........................................................................................................................................29-6

TestingtheT ow/RunSwitch......................................................................................................................29-6

Tow/RunSwitchRemoval.........................................................................................................................29-6

Tow/RunSwitchInstallation......................................................................................................................29-6

MotorControllerOutputRegulator(MCOR)...................................................................................................29-7

TestingtheMCOR...................................................................................................................................29-7

MCORRemoval......................................................................................................................................29-7

MCORInstallation...................................................................................................................................29-7

ReverseBuzzer...........................................................................................................................................29-8

TestingtheReverseBuzzer......................................................................................................................29-8

ReverseBuzzerRemoval.........................................................................................................................29-8

ReverseBuzzerInstallation......................................................................................................................29-8

Pagexiv2014Precedent®GolfCarMaintenanceandServiceManual

ElectronicsModule......................................................................................................................................29-9

ElectronicsModuleRemoval....................................................................................................................29-9

ElectronicsModuleInstallation................................................................................................................29-10

SpeedController........................................................................................................................................29-11

TestingtheSolidStateSpeedController..................................................................................................29-11

SpeedControllerRemoval......................................................................................................................29-11

SpeedControllerInstallation....................................................................................................................29-11

Solenoid.....................................................................................................................................................29-12

TestingtheSolenoid...............................................................................................................................29-12

SolenoidRemoval..................................................................................................................................29-13

SolenoidInstallation................................................................................................................................29-13

ChargerReceptacle....................................................................................................................................29-13

TestingtheChargerReceptacle...............................................................................................................29-13

ChargerReceptacleInspection................................................................................................................29-13

ChargerReceptacleRemoval..................................................................................................................29-14

ChargerReceptacleInstallation...............................................................................................................29-14

SECTION30–BATTERIES:ELECTRICVEHICLEWITHERICCHARGING......................................................30-1

GeneralInformation.....................................................................................................................................30-1

BatteryTestingBasics–8Volt......................................................................................................................30-2

Observation.............................................................................................................................................30-2

MeasuringVoltageofBatterySet..............................................................................................................30-2

BatteryCellNumbering............................................................................................................................30-2

BatteryTesting–8Volt................................................................................................................................30-3

BatteryRegrouping......................................................................................................................................30-3

BatteryReplacement...................................................................................................................................30-5

BatteryCare................................................................................................................................................30-6

WaterQuality..........................................................................................................................................30-6

BatteryCare–VehiclesEquippedwiththeSingle-PointWateringSystem...................................................30-7

BatteryCare–VehiclesWithouttheSingle-PointWateringSystem.............................................................30-8

Self-Discharge.........................................................................................................................................30-9

ElectrolyteLevel......................................................................................................................................30-9

VibrationDamage...................................................................................................................................30-10

SinglePointWateringSystem(SPWS).........................................................................................................30-11

InitialMaintenanceoftheSPWS..............................................................................................................30-11

WateringBatterieswiththeSPWS...........................................................................................................30-11

BatteryStorage..........................................................................................................................................30-13

FleetRotation.............................................................................................................................................30-13

Deep-Discharge.........................................................................................................................................30-13

EarlyExcessiveDischarging.......................................................................................................................30-13

SECTION31–BATTERYCHARGER:FORERICCHARGINGSYSTEM...........................................................31-1

GeneralInformation.....................................................................................................................................31-2

USBServicePort.....................................................................................................................................31-3

ULandCSAListing.................................................................................................................................31-3

CECompliance.......................................................................................................................................31-3

PlugandReceptacle................................................................................................................................31-3

ChargerPowerConnectionFuse..............................................................................................................31-4

ChargerInterlock.....................................................................................................................................31-4

ACInputVoltageDetection......................................................................................................................31-4

ThermalCutback.....................................................................................................................................31-4

ChargeIndicatorLight..............................................................................................................................31-4

ChargerStatusIndicators.........................................................................................................................31-5

Long-termStorage...................................................................................................................................31-5

ExternalChargerMounting...........................................................................................................................31-6

ACPowerConnection..................................................................................................................................31-7

TheChargeCircuit.......................................................................................................................................31-8

ChargerOperation.......................................................................................................................................31-9

ChargingBatteries...................................................................................................................................31-9

ChargerMaintenance.................................................................................................................................31-12

ChargerTroubleshooting.............................................................................................................................31-13

NumberingVehiclesandChargers...........................................................................................................31-13

2014Precedent®GolfCarMaintenanceandServiceManualPagexv

USBServicePort....................................................................................................................................31-13

IncomingACService..............................................................................................................................31-13

TerminalBlockCover..............................................................................................................................31-14

ResettingPower–ExternalCharger........................................................................................................31-14

ResettingPower–OnboardCharger.......................................................................................................31-14

ChargerTroubleshootingIndicators.........................................................................................................31-15

TestProcedures.........................................................................................................................................31-16

ExternalChargerRepairs............................................................................................................................31-19

TerminalBlockCoverRemoval................................................................................................................31-19

TerminalBlockCoverInstallation.............................................................................................................31-20

DCCordandStrainReliefRemoval.........................................................................................................31-20

DCCordandStrainReliefInstallation......................................................................................................31-20

HandleRemoval.....................................................................................................................................31-21

HandleInstallation..................................................................................................................................31-21

FootRemoval.........................................................................................................................................31-21

FootInstallation......................................................................................................................................31-21

OnboardChargerRepairs...........................................................................................................................31-22

OnboardChargerRemoval.....................................................................................................................31-22

OnboardChargerInstallation...................................................................................................................31-23

TerminalBlockCoverRemoval................................................................................................................31-23

TerminalBlockCoverInstallation.............................................................................................................31-23

DCCordandStrainReliefRemoval.........................................................................................................31-24

DCCordandStrainReliefInstallation......................................................................................................31-24

DCChargingHarnessRemoval...............................................................................................................31-24

DCChargingHarnessInstallation............................................................................................................31-25

SECTIONi–INDEX

Pagexvi2014Precedent®GolfCarMaintenanceandServiceManual

SECTION1–SAFETY1

SAFETYDETAILS

ToensurethesafetyofthoseservicingClubCarvehicles,andtoprotectthevehiclesfrompossibledamageresulting

fromimproperserviceormaintenance,theproceduresinthismanualmustbefollowed.

ItisimportanttonotethatthroughoutthismanualtherearestatementslabeledDANGER,WARNING,orCAUTION.

Thesespecialstatementsrelatetospecicsafetyissues,andmustberead,understood,andheededbefore

proceedingwithprocedures.TherearestatementslabeledNOTE,whichprovideotheressentialserviceor

maintenanceinformation.

PERSONALSAFETY

DANGER

•ADANGERindicatesanimmediatehazardthatwillresultinseverepersonalinjuryordeath.The

colorassociatedwithDangerisRED.

WARNING

•AWARNINGindicatesanimmediatehazardthatcouldresultinseverepersonalinjuryordeath.

ThecolorassociatedwithWarningisORANGE.

CAUTION

•ACAUTIONwiththesafetyalertsymbolindicatesahazardorunsafepracticethatcouldresultin

minorpersonalinjury.ThecolorassociatedwithCautionisYELLOW.

MACHINESAFETY

CAUTION

•ACAUTIONwithoutthesafetyalertsymbolindicatesapotentiallyhazardoussituationthatcould

resultinpropertydamage.

ACAUTION,withoutthesafetyalertsymbol,isintendedformachineandpropertysafety.Itisusedthroughoutthis

manualfollowedbyspecicinstructionstopreventmachineorpropertydamage.FailuretofollowtheseCAUTION

messagescouldresultinmachineorpropertydamage.

INFORMATION

NOTE:Instructionsthatclarifysteps,procedures,orotherinformationinthismanual.

2014Precedent®GolfCarMaintenanceandServiceManualPage1-1

1GeneralWarningsSAFETY

GENERALWARNINGS

Thefollowingsafetystatementsmustbeheededwheneverthevehicleisbeingoperated,repaired,orserviced.Other

specicsafetystatementsappearthroughoutthismanualandonthevehicle.

DANGER

•Battery–Explosivegases!Donotsmoke.Keepsparksandamesawayfromthevehicleandservice

area.Ventilatewhenchargingoroperatingvehicleinanenclosedarea.Wearafullfaceshieldand

rubbergloveswhenworkingonornearbatteries.

•Topreventre,immediatelyreplacebatterychargerDCcordplugandreceptacleifthefollowing

conditionsexist:

–Plugpinshavewornnickelplatingandcopperisexposed.

–Plugrequiresaninordinateamountofforcetoinsertintoreceptacle,especiallyifaccompanied

bya“grinding”feel.

•Battery–Poison!Containsacid!Causessevereburns.Avoidcontactwithskin,eyes,orclothing.

Antidotes:

–External:Flushwithwater.Callaphysicianimmediately.

–Internal:Drinklargequantitiesofmilkorwater.Followwithmilkofmagnesiaorvegetable

oil.Callaphysicianimmediately.

–Eyes:Flushwithwaterfor15minutes.Callaphysicianimmediately.

•Gasoline–Flammable!Explosive!Donotsmoke.Keepsparksandamesawayfromthevehicleand

servicearea.Serviceonlyinawell-ventilatedarea.

•Donotoperateengineinanenclosedareawithoutproperventilation.Theengineproducescarbon

monoxide,whichisanodorless,deadlypoison.

•Thevehiclewillnotprovideprotectionfromlightning,yingobjects,orotherstorm-relatedhazards.If

caughtinastormwhiledrivingaClubCarvehicle,exitthevehicleandseekshelterinaccordancewith

applicablesafetyguidelinesforyourlocation.

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.

WARNINGCONTINUEDONNEXTPAGE

Page1-22014Precedent®GolfCarMaintenanceandServiceManual

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