Club car 2009-20011 electric precedent Manual

2009-201 1 Electric Precedent

Maintenance and

Service Manual

IQ System and Excel System V ehicles

Manual Number 103472701

Edition Code 0309C1 1 10B

FOREWORD

ClubCarvehiclesaredesignedandbuilttoprovidetheultimateinperformanceefciency;however,proper

maintenanceandrepairareessentialforachievingmaximumservicelifeandcontinuedsafeandreliableoperation.

ThismanualprovidesdetailedinformationforthemaintenanceandrepairoftheelectricPrecedentvehicles,and

shouldbethoroughlyreviewedpriortoservicingthevehicle.Theproceduresprovidedhereinmustbeproperly

implemented,andtheDANGER,WARNING,andCAUTIONstatementsmustbeheeded.

Thismanualwaswrittenforthetrainedtechnicianwhoalreadypossessesknowledgeandskillsinelectricaland

mechanicalrepair.Ifthetechniciandoesnothavesuchknowledgeandskills,attemptedserviceorrepairstothe

vehiclemayrenderthevehicleunsafe.Forthisreason,ClubCaradvisesthatallrepairsand/orservicebeperformed

byanauthorizedClubCardistributor/dealerrepresentativeorbyaClubCarfactory-trainedtechnician.

ItisthepolicyofClubCar,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

ThismanualeffectiveAugust4,2008

2009-2011ElectricPrecedentMaintenanceandServiceManualPagei

CONTENTS

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

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

DisablingtheVehicle..................................................................................................................................1-2

DisconnectingtheBatteries–ElectricVehicles............................................................................................1-3

ConnectingtheBatteries–ElectricVehicles................................................................................................1-3

RecyclingLead-AcidBatteries....................................................................................................................1-3

Internationalsafetysymbolsonbatteries.....................................................................................................1-4

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

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

SerialNumberIdentication............................................................................................................................3-1

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

Storage.........................................................................................................................................................3-2

PreparingtheElectricVehicleforExtendedOff-SeasonStorage...................................................................3-3

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

SECTION4–BODYANDTRIM.........................................................................................................................4-1

CleaningtheVehicle......................................................................................................................................4-1

Seat..........................................................................................................................................................4-1

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

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

MinorImpactDamage/Deformations...........................................................................................................4-2

MinorScratchesandSurfaceBlemishes.....................................................................................................4-3

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

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

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

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

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

InstrumentPanel...........................................................................................................................................4-6

InstrumentPanelRemoval.........................................................................................................................4-6

InstrumentPanelInstallation......................................................................................................................4-6

FloorMatandRetainers.................................................................................................................................4-7

FloorMatRetainerRemoval.......................................................................................................................4-7

FloorMatRetainerInstallation....................................................................................................................4-7

KickPlateandChargerReceptacleBezel.......................................................................................................4-8

KickPlateandChargerReceptacleBezelRemoval.....................................................................................4-8

KickPlateandChargerReceptacleBezelInstallation...................................................................................4-8

RearBody–Two-PassengerVehicles.............................................................................................................4-9

UniversalAccessoryMounting....................................................................................................................4-9

BackrestandStructuralAccessoryModule(SAM).......................................................................................4-9

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

RearBody–Four-PassengerVehicles..........................................................................................................4-13

SeatBacks..............................................................................................................................................4-13

SeatSupport...........................................................................................................................................4-13

FootDeck...............................................................................................................................................4-14

RearBodyComponents(Four-Passenger)................................................................................................4-15

Canopy–Two-Passenger............................................................................................................................4-16

Two-PassengerCanopyRemoval.............................................................................................................4-16

Two-PassengerCanopyInstallation..........................................................................................................4-18

Canopy–Four-Passenger...........................................................................................................................4-18

Four-PassengerCanopyRemoval............................................................................................................4-18

Four-PassengerCanopyInstallation.........................................................................................................4-19

Canopy(MonsoonVersion)–Four-Passenger...............................................................................................4-21

MonsoonCanopyRemoval......................................................................................................................4-21

MonsoonCanopyInstallation....................................................................................................................4-21

2009-2011ElectricPrecedentMaintenanceandServiceManualPageiii

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

PedalGroup–ThrottlePositionSensor...........................................................................................................5-1

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

ThrottlePositionSensor(TPS)...................................................................................................................5-3

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

PedalGroup–MCOR....................................................................................................................................5-3

PedalGroupRemoval................................................................................................................................5-3

PedalGroupInstallation.............................................................................................................................5-4

MCOR......................................................................................................................................................5-4

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

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

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

BrakePedalRemoval....................................................................................................................................5-6

BrakePedalInstallation.................................................................................................................................5-6

SECTION6–WHEELBRAKEASSEMBLIES....................................................................................................6-1

GeneralInformation.......................................................................................................................................6-1

BrakeShoeRemoval.....................................................................................................................................6-1

BrakeAssemblyCleaning..............................................................................................................................6-5

BrakeShoeInstallation..................................................................................................................................6-7

BrakeCableEqualizerAdjustment................................................................................................................6-10

BrakeClusterRemovalandInstallation..........................................................................................................6-11

BrakeClusterRemoval.............................................................................................................................6-11

BrakeClusterInstallation..........................................................................................................................6-11

BrakeCableRemovalandInstallation...........................................................................................................6-13

BrakeCableRemoval..............................................................................................................................6-13

BrakeCableInstallation...........................................................................................................................6-14

SECTION7–STEERINGANDFRONTSUSPENSION.......................................................................................7-1

GeneralInformation.......................................................................................................................................7-1

SteeringWheel..............................................................................................................................................7-1

SteeringWheelRemoval............................................................................................................................7-1

SteeringWheelInstallation.........................................................................................................................7-2

SteeringColumn............................................................................................................................................7-2

SteeringColumnRemoval..........................................................................................................................7-2

SteeringColumnInstallation.......................................................................................................................7-3

RackandPinion............................................................................................................................................7-4

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

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

RackandPinionDisassembly....................................................................................................................7-5

RackandPinionAssembly.........................................................................................................................7-8

RackandPinionInstallation.......................................................................................................................7-9

FrontSuspension.........................................................................................................................................7-11

Lubrication...............................................................................................................................................7-11

WheelAlignment......................................................................................................................................7-11

FrontSuspensionComponents.....................................................................................................................7-13

TieRodEndRemoval..............................................................................................................................7-13

TieRodInstallation..................................................................................................................................7-13

LeafSpringRemoval...............................................................................................................................7-14

LeafSpringInstallation.............................................................................................................................7-14

KingpinandSteeringSpindleRemoval.....................................................................................................7-14

KingpinandSteeringSpindleInstallation...................................................................................................7-14

ControlArmRemoval...............................................................................................................................7-15

ControlArmInstallation............................................................................................................................7-15

ShockAbsorberRemoval.........................................................................................................................7-15

ShockAbsorberInstallation......................................................................................................................7-15

FrontWheelBearingsandHubs...................................................................................................................7-18

FrontWheelFreePlayInspection.............................................................................................................7-18

FrontHubRemoval..................................................................................................................................7-18

HubInstallation........................................................................................................................................7-18

Pageiv2009-2011ElectricPrecedentMaintenanceandServiceManual

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

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

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

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

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

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

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

TireRepair................................................................................................................................................8-2

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

SECTION9–REARSUSPENSION...................................................................................................................9-1

GeneralInformation.......................................................................................................................................9-1

ShockAbsorbers...........................................................................................................................................9-1

ShockAbsorberRemovalandInspection....................................................................................................9-1

ShockAbsorberInstallation........................................................................................................................9-1

LeafSprings(Two-PassengerVehicles)..........................................................................................................9-2

LeafSpringRemoval(Two-PassengerVehicles)..........................................................................................9-2

LeafSpringInstallation(Two-PassengerVehicles).......................................................................................9-3

LeafSprings(Four-PassengerVehicles).........................................................................................................9-4

LeafSpringRemoval(Four-PassengerVehicles).........................................................................................9-4

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

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

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

GeneralInformation.....................................................................................................................................10-3

PeriodicServiceSchedule............................................................................................................................10-3

PeriodicLubricationSchedule......................................................................................................................10-6

SECTION11–IQSYSTEMTROUBLESHOOTING–TPS..................................................................................11-1

GeneralInformation......................................................................................................................................11-1

WiringDiagrams...........................................................................................................................................11-2

Troubleshooting............................................................................................................................................11-7

TroubleshootingtheVehiclewiththeIQDM................................................................................................11-7

TroubleshootingGuide1...........................................................................................................................11-8

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

TestProcedures.........................................................................................................................................11-13

BatteryWarningLight..................................................................................................................................11-35

CommunicationDisplayModule(CDM)........................................................................................................11-35

UsingtheCDMtoRetrieveDatafromtheOnboardComputer...................................................................11-36

CDMTroubleshootingGuide.......................................................................................................................11-38

SECTION12–IQSYSTEMTROUBLESHOOTING–MCOR.............................................................................12-1

GeneralInformation.....................................................................................................................................12-1

WiringDiagrams..........................................................................................................................................12-2

Troubleshooting...........................................................................................................................................12-7

TroubleshootingtheVehiclewiththeIQDM...............................................................................................12-7

TroubleshootingGuide1..........................................................................................................................12-8

TroubleshootingGuide2.........................................................................................................................12-11

TestProcedures.........................................................................................................................................12-13

BatteryWarningLight..................................................................................................................................12-38

CommunicationDisplayModule(CDM)........................................................................................................12-39

UsingtheCDMtoRetrieveDatafromtheOnboardComputer...................................................................12-40

CDMTroubleshootingGuide.......................................................................................................................12-40

SECTION13–EXCELSYSTEMTROUBLESHOOTING–TPS.........................................................................13-1

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

DifferencesBetweentheExcelandIQSystems.........................................................................................13-1

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

2009-2011ElectricPrecedentMaintenanceandServiceManualPagev

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

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

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

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

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

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

BatteryWarningLight..................................................................................................................................13-35

CommunicationDisplayModule(CDM)........................................................................................................13-35

UsingtheCDMtoRetrieveDatafromtheOnboardComputer...................................................................13-36

CDMTroubleshootingGuide.......................................................................................................................13-38

SECTION14–EXCELSYSTEMTROUBLESHOOTING–MCOR.....................................................................14-1

GeneralInformation.....................................................................................................................................14-1

DifferencesBetweentheExcelandIQSystems.........................................................................................14-1

Features.................................................................................................................................................14-2

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

Troubleshooting...........................................................................................................................................14-8

TroubleshootingtheVehiclewiththeIQDM...............................................................................................14-8

TroubleshootingGuide1..........................................................................................................................14-8

TroubleshootingGuide2.........................................................................................................................14-11

TestProcedures.........................................................................................................................................14-13

BatteryWarningLight..................................................................................................................................14-38

CommunicationDisplayModule(CDM)........................................................................................................14-38

UsingtheCDMtoRetrieveDatafromtheOnboardComputer...................................................................14-39

CDMTroubleshootingGuide.......................................................................................................................14-40

SECTION15–IQDISPLAYMODULE(IQDM)ANDIQDM-PDIAGNOSTICS:IQSYSTEM................................15-1

PluggingtheHandsetintotheVehicle...........................................................................................................15-1

IntroductoryDisplay.....................................................................................................................................15-1

MenuNavigation.........................................................................................................................................15-2

Program(IQDM-Ponly)...........................................................................................................................15-3

Monitor...................................................................................................................................................15-3

Faults.....................................................................................................................................................15-4

Functions................................................................................................................................................15-4

Information..............................................................................................................................................15-4

ProgrammerSetup..................................................................................................................................15-4

MonitorMenu..............................................................................................................................................15-4

Throttle...................................................................................................................................................15-4

BattVoltage.............................................................................................................................................15-5

Heatsink..................................................................................................................................................15-5

ArmCurrent............................................................................................................................................15-5

FieldCurrent...........................................................................................................................................15-5

ArmPWM...............................................................................................................................................15-5

FieldPWM..............................................................................................................................................15-5

SpeedPulses..........................................................................................................................................15-5

FootInput...............................................................................................................................................15-5

ForwardInput..........................................................................................................................................15-6

ReverseInput..........................................................................................................................................15-6

MainCont...............................................................................................................................................15-6

KeyInput................................................................................................................................................15-6

PasswordTries(IQDM-Ponly).................................................................................................................15-6

10.3Transaxle.........................................................................................................................................15-6

20+Speed..............................................................................................................................................15-6

FaultsMenu................................................................................................................................................15-7

SystemFaults.........................................................................................................................................15-7

HWFailsafe............................................................................................................................................15-9

KEYSWITCHSRO(StaticReturntoOff)..................................................................................................15-9

ThrottleFault1.......................................................................................................................................15-10

Speedsensor.........................................................................................................................................15-10

MainWelded..........................................................................................................................................15-10

MainDriverOn.......................................................................................................................................15-10

MainDriverOff.......................................................................................................................................15-10

Pagevi2009-2011ElectricPrecedentMaintenanceandServiceManual

HighSpeedWalkaway............................................................................................................................15-10

MainCoilFAULT.....................................................................................................................................15-10

FieldMissing..........................................................................................................................................15-11

HPD......................................................................................................................................................15-11

Proc/Wiring............................................................................................................................................15-11

Overvoltage............................................................................................................................................15-11

LowBatteryVoltage................................................................................................................................15-11

ThermalCutback....................................................................................................................................15-11

MotorStall..............................................................................................................................................15-11

MainDropout.........................................................................................................................................15-11

OpenArmature.......................................................................................................................................15-12

IncorrectPassword(IQDM-Ponly)...........................................................................................................15-12

MaxPasswordTries(IQDM-Ponly).........................................................................................................15-12

FaultHistory...........................................................................................................................................15-12

ClearingFaultHistory.............................................................................................................................15-12

FunctionsMenu..........................................................................................................................................15-13

GetSettingsFromController...................................................................................................................15-13

WriteSettingstoController......................................................................................................................15-14

ResetAllSettings...................................................................................................................................15-15

Information.................................................................................................................................................15-16

ModelNumber........................................................................................................................................15-16

SerialNumber........................................................................................................................................15-16

MFGDate..............................................................................................................................................15-16

SoftwareVersion....................................................................................................................................15-16

ProgrammerSetup.....................................................................................................................................15-17

Program.................................................................................................................................................15-17

Faults....................................................................................................................................................15-17

Information.............................................................................................................................................15-17

IQDMandIQDM-PHandsetTroubleshooting...............................................................................................15-18

TestProcedures.........................................................................................................................................15-19

SECTION16–IQDISPLAYMODULE(IQDM)ANDIQDM-PDIAGNOSTICS:EXCELSYSTEM.........................16-1

PluggingtheHandsetintotheVehicle...........................................................................................................16-1

IntroductoryDisplay.....................................................................................................................................16-2

MenuNavigation.........................................................................................................................................16-3

Program(IQDM-Ponly)...........................................................................................................................16-3

Monitor...................................................................................................................................................16-3

Faults.....................................................................................................................................................16-3

Functions................................................................................................................................................16-3

Information..............................................................................................................................................16-4

ProgrammerSetup..................................................................................................................................16-4

MonitorMenu..............................................................................................................................................16-4

Speed.....................................................................................................................................................16-4

Throttle...................................................................................................................................................16-4

BattAuxVoltage......................................................................................................................................16-5

Temperature(sameasHeatsinkinIQSystem)..........................................................................................16-5

ArmCurrent............................................................................................................................................16-5

FieldCurrent...........................................................................................................................................16-5

ArmaturePWM........................................................................................................................................16-5

FieldPWM..............................................................................................................................................16-5

BrakeVoltsIn..........................................................................................................................................16-5

SpeedPulses..........................................................................................................................................16-5

FootInput...............................................................................................................................................16-6

KeyInput................................................................................................................................................16-6

ForwardInput..........................................................................................................................................16-6

ReverseInput..........................................................................................................................................16-6

ChargerInhibit.........................................................................................................................................16-6

MainContDriver.....................................................................................................................................16-6

PasswordTries(IQDM-POnly).................................................................................................................16-6

Odometer................................................................................................................................................16-7

VehicleSpeeds(IQDM-POnly).................................................................................................................16-7

PedalCounters........................................................................................................................................16-7

FaultCounters.........................................................................................................................................16-7

2009-2011ElectricPrecedentMaintenanceandServiceManualPagevii

FaultCountOdometers............................................................................................................................16-7

NegIA250..............................................................................................................................................16-7

NegIA300..............................................................................................................................................16-7

FaultsMenu................................................................................................................................................16-8

SystemFaults.........................................................................................................................................16-8

HWFailsafe...........................................................................................................................................16-10

ThrottleFault..........................................................................................................................................16-10

Speedsensor.........................................................................................................................................16-11

MainWelded..........................................................................................................................................16-11

MainDriverOn.......................................................................................................................................16-11

MainDriverOff.......................................................................................................................................16-11

MainCoilOpen.......................................................................................................................................16-11

FLD(Field)Missing.................................................................................................................................16-12

HPD......................................................................................................................................................16-12

Overvoltage............................................................................................................................................16-12

LowBatteryVoltage(Undervoltage).........................................................................................................16-12

ThermalCutback....................................................................................................................................16-12

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

MainDropout(1or2)..............................................................................................................................16-13

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

IncorrectPassword(IQDM-Ponly)...........................................................................................................16-13

MaxPasswordTries(IQDM-Ponly).........................................................................................................16-13

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

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

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

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

WriteSettingstoController......................................................................................................................16-15

ResetAllSettings...................................................................................................................................16-16

Information.................................................................................................................................................16-17

ModelNumber........................................................................................................................................16-17

SerialNumber........................................................................................................................................16-17

MFGDate..............................................................................................................................................16-17

SoftwareVersion....................................................................................................................................16-17

ProgrammerSetup.....................................................................................................................................16-18

Program.................................................................................................................................................16-18

Faults....................................................................................................................................................16-18

Information.............................................................................................................................................16-18

IQDMandIQDM-PHandsetTroubleshooting...............................................................................................16-19

TestProcedures.........................................................................................................................................16-20

SECTION17–ELECTRICALCOMPONENTS..................................................................................................17-1

KeySwitch..................................................................................................................................................17-1

TestingtheKeySwitch.............................................................................................................................17-1

KeySwitchRemoval................................................................................................................................17-1

KeySwitchInstallation.............................................................................................................................17-1

BatteryWarningLight...................................................................................................................................17-2

TestingtheBatteryWarningLight..............................................................................................................17-2

BatteryWarningLightRemoval................................................................................................................17-2

BatteryWarningLightInstallation..............................................................................................................17-3

Forward/ReverseRockerSwitch...................................................................................................................17-3

TestingtheForward/ReverseRockerSwitch..............................................................................................17-3

Forward/ReverseRockerSwitchRemoval.................................................................................................17-3

Forward/ReverseRockerSwitchInstallation..............................................................................................17-4

ElectronicsModuleCover.............................................................................................................................17-5

ElectronicsModuleCoverRemoval..........................................................................................................17-5

ElectronicsModuleCoverInstallation........................................................................................................17-5

Tow/RunSwitch...........................................................................................................................................17-6

TestingtheTow/RunSwitch......................................................................................................................17-6

Tow/RunSwitchRemoval.........................................................................................................................17-6

Tow/RunSwitchInstallation......................................................................................................................17-6

ThrottlePositionSensor(TPS).....................................................................................................................17-7

TestingtheThrottlePositionSensor..........................................................................................................17-7

ThrottlePositionSensorReplacement......................................................................................................17-7

Pageviii2009-2011ElectricPrecedentMaintenanceandServiceManual

MotorControllerOutputRegulator(MCOR)...................................................................................................17-8

TestingtheMCOR...................................................................................................................................17-8

MCORRemoval......................................................................................................................................17-8

MCORInstallation...................................................................................................................................17-8

ReverseBuzzer...........................................................................................................................................17-8

TestingtheReverseBuzzer......................................................................................................................17-8

ReverseBuzzerRemoval.........................................................................................................................17-8

ReverseBuzzerInstallation......................................................................................................................17-9

ElectronicsModule......................................................................................................................................17-9

ElectronicsModuleRemoval....................................................................................................................17-9

ElectronicsModuleInstallation................................................................................................................17-10

SpeedController........................................................................................................................................17-12

TestingtheSolidStateSpeedController..................................................................................................17-12

SpeedControllerRemoval......................................................................................................................17-12

SpeedControllerInstallation....................................................................................................................17-12

Solenoid.....................................................................................................................................................17-13

TestingtheSolenoid...............................................................................................................................17-13

SolenoidRemoval..................................................................................................................................17-13

SolenoidInstallation................................................................................................................................17-13

OnboardComputer(OBC)...........................................................................................................................17-14

TestingtheOnboardComputer................................................................................................................17-14

OnboardComputerRemoval...................................................................................................................17-14

OnboardComputerInstallation................................................................................................................17-14

ChargerReceptacle....................................................................................................................................17-15

TestingtheChargerReceptacle...............................................................................................................17-15

ChargerReceptacleInspection................................................................................................................17-15

ChargerReceptacleRemoval..................................................................................................................17-15

ChargerReceptacleInstallation...............................................................................................................17-16

HeadlightAdjustment..................................................................................................................................17-16

AimingtheHeadlightBeam.....................................................................................................................17-16

FerriteBeads–CEMarkVehicles...............................................................................................................17-18

SECTION18–BATTERIES.............................................................................................................................18-1

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

BatteryTroubleshootingChart......................................................................................................................18-2

BatteryTesting–12Volt...............................................................................................................................18-3

BatteryChargerTest................................................................................................................................18-3

On-ChargeVoltageT est...........................................................................................................................18-3

HydrometerTest......................................................................................................................................18-3

DischargeTest........................................................................................................................................18-6

BatteryTroubleshootingExamples............................................................................................................18-8

BatteryTesting–8Volt................................................................................................................................18-9

BatteryChargerTest................................................................................................................................18-9

On-ChargeVoltageT est...........................................................................................................................18-9

HydrometerTest......................................................................................................................................18-9

DischargeTest.......................................................................................................................................18-12

BatteryTroubleshootingExamples...........................................................................................................18-14

BatteryReplacement..................................................................................................................................18-15

BatteryCare...............................................................................................................................................18-16

WaterQuality.........................................................................................................................................18-16

BatteryCare–VehiclesEquippedwiththeSingle-PointWateringSystem..................................................18-17

BatteryCare–VehiclesWithouttheSingle-PointWateringSystem............................................................18-18

Self-Discharge........................................................................................................................................18-19

ElectrolyteLevel.....................................................................................................................................18-19

VibrationDamage...................................................................................................................................18-20

BatteryCharger–HighFrequency...............................................................................................................18-20

BatteryCharger–Ferroresonant.................................................................................................................18-21

ChargingBatteries..................................................................................................................................18-22

PlugandReceptacle...............................................................................................................................18-24

ChargerShutsOffAfter16Hours............................................................................................................18-24

Deep-Discharge.....................................................................................................................................18-24

EarlyExcessiveDischarging...................................................................................................................18-24

IncomingACService..............................................................................................................................18-24

2009-2011ElectricPrecedentMaintenanceandServiceManualPageix

FleetRotation.........................................................................................................................................18-25

NumberingVehiclesandChargers...........................................................................................................18-25

SinglePointWateringSystem(SPWS).........................................................................................................18-25

InitialMaintenanceoftheSPWS..............................................................................................................18-25

WateringBatterieswiththeSPWS...........................................................................................................18-26

BatteryStorage..........................................................................................................................................18-28

ChargingaBatteryPackthathasLowVoltage.............................................................................................18-28

SECTION19–BATTERYCHARGER..............................................................................................................19-1

SECTION20–MOTOR(MODELEJ4-4001ANDEJ8-4001A)...........................................................................20-1

GeneralInformation.....................................................................................................................................20-1

MotorIdentication......................................................................................................................................20-1

ExternalMotorTesting.................................................................................................................................20-2

Motor..........................................................................................................................................................20-3

MotorRemoval........................................................................................................................................20-3

MotorDisassembly..................................................................................................................................20-5

MotorComponentTestingandInspection......................................................................................................20-7

ArmatureInspectionandTesting...............................................................................................................20-7

MotorFrameandFieldWindingsInspection..............................................................................................20-9

MotorBrush,Spring,andTerminalInsulatorInspection..............................................................................20-9

ReconditioningtheMotor............................................................................................................................20-12

MotorSpecications...............................................................................................................................20-12

MotorAssembly..........................................................................................................................................20-12

MotorInstallation........................................................................................................................................20-14

SECTION21–TRANSAXLE(TYPEG)............................................................................................................21-1

Lubrication..................................................................................................................................................21-1

AxleBearingandShaft................................................................................................................................21-1

AxleShaft...............................................................................................................................................21-1

AxleBearing............................................................................................................................................21-4

Transaxle....................................................................................................................................................21-5

TransaxleRemoval..................................................................................................................................21-5

TransaxleDisassembly,Inspection,andAssembly.........................................................................................21-8

TransaxleDisassemblyandInspection......................................................................................................21-8

TransaxleAssembly................................................................................................................................21-10

TransaxleInstallation..................................................................................................................................21-11

SECTION22–IQDISPLAYMODULEPROGRAMMER(IQDM-P):IQSYSTEM.................................................22-1

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

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

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

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

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

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

CodeA,CodeB,andCodeC...................................................................................................................22-3

SlowPedalUp.........................................................................................................................................22-4

KSISROEnable......................................................................................................................................22-4

M2MaxSpeed........................................................................................................................................22-4

SECTION23–IQDISPLAYMODULEPROGRAMMER(IQDM-P):EXCELSYSTEM.........................................23-1

PluggingtheHandsetintotheVehicle...........................................................................................................23-1

ProgramMenu............................................................................................................................................23-2

SpeedSetting..........................................................................................................................................23-3

FastAccel...............................................................................................................................................23-3

PedalUpMode........................................................................................................................................23-3

SpeedCal...............................................................................................................................................23-3

S3FWDSpeed.......................................................................................................................................23-4

CodeA,CodeB,andCodeC...................................................................................................................23-4

Pagex2009-2011ElectricPrecedentMaintenanceandServiceManual

VehicleS/N.............................................................................................................................................23-4

VehicleDecal..........................................................................................................................................23-4

SECTIONi–INDEX

2009-2011ElectricPrecedentMaintenanceandServiceManualPagexi

SECTION1–SAFETY1

ToensurethesafetyofthoseservicingClubCarvehicles,andtoprotectthevehiclesfrompossibledamageresulting

fromimproperserviceormaintenance,theproceduresinthismanualmustbefollowed.

ItisimportanttonotethatthroughoutthismanualtherearestatementslabeledDANGER,WARNING,orCAUTION.

Thesespecialstatementsrelatetospecicsafetyissues,andmustberead,understood,andheededbefore

proceedingwithprocedures.TherearestatementslabeledNOTE,whichprovideotheressentialserviceor

maintenanceinformation.

DANGER

•ADANGERindicatesanimmediatehazardthatwillresultinseverepersonalinjuryordeath.

WARNING

•AWARNINGindicatesanimmediatehazardthatcouldresultinseverepersonalinjuryordeath.

CAUTION

•ACAUTIONwiththesafetyalertsymbolindicatesahazardorunsafepracticethatcouldresultin

minorpersonalinjury.

CAUTION

•ACAUTIONwithoutthesafetyalertsymbolindicatesapotentiallyhazardoussituationthatcould

resultinpropertydamage.

GENERALWARNINGS

Thefollowingsafetystatementsmustbeheededwheneverthevehicleisbeingoperated,repaired,orserviced.Other

specicsafetystatementsappearthroughoutthismanualandonthevehicle.

DANGER

•Battery–Explosivegases!Donotsmoke.Keepsparksandamesawayfromthevehicleandservice

area.Ventilatewhenchargingoroperatingvehicleinanenclosedarea.Wearafullfaceshieldand

rubbergloveswhenworkingonornearbatteries.

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

Antidotes:

–External:Flushwithwater.Callaphysicianimmediately.

–Internal:Drinklargequantitiesofmilkorwater.Followwithmilkofmagnesiaorvegetable

oil.Callaphysicianimmediately.

–Eyes:Flushwithwaterfor15minutes.Callaphysicianimmediately.

2009-2011ElectricPrecedentMaintenanceandServiceManualPage1-1

1GeneralWarningsSAFETY

WARNING

•Onlytrainedtechniciansshouldserviceorrepairthevehicleorbatterycharger.Anyonedoingeven

simplerepairsorserviceshouldhaveknowledgeandexperienceinelectricalandmechanicalrepair.

Theappropriateinstructionsmustbeusedwhenperformingmaintenance,service,oraccessory

installation.

•Followtheproceduresexactlyasstatedinthismanual,andheedallDANGER,WARNING,and

CAUTIONstatementsinthismanualaswellasthoseonthevehicleandbatterycharger.

•Liftonlyoneendofthevehicleatatime.Useasuitableliftingdevice(chainhoistorhydraulicoor

jack)with1000lb.(454kg)minimumliftingcapacity.Donotuseliftingdevicetoholdvehicleinraised

position.Useapprovedjackstandsofproperweightcapacitytosupportthevehicleandchock

thewheelsthatremainontheoor.Whennotperformingatestorserviceprocedurethatrequires

movementofthewheels,lockthebrakes.

•Improperuseofthevehicleorfailuretoproperlymaintainitcouldresultindecreasedvehicle

performance,severepersonalinjury,ordeath.

•Anymodicationorchangetothevehiclethataffectsthestabilityorhandlingofthevehicle,or

increasesmaximumvehiclespeedbeyondfactoryspecications,couldresultinseverepersonal

injuryordeath.

•Checkthevehicleforproperlocationofallvehiclesafetyandoperationdecalsandmakesuretheyare

inplaceandareeasytoread.

•Wearsafetyglassesorapprovedeyeprotectionwhenservicingthevehicleorbatterycharger.Weara

fullfaceshieldandrubbergloveswhenworkingonornearbatteries.

•Donotwearlooseclothingorjewelrysuchasrings,watches,chains,etc.,whenservicingthe

vehicleorbatterycharger.

•Useinsulatedtoolswhenworkingnearbatteriesorelectricalconnections.Useextremecautionto

avoidshortingofcomponentsorwiring.

•Priortoleavingthevehicleunattendedorservicingthevehicle,settheparkbrake,turnthekeyswitch

OFF,removethekey,andplacetheForward/ReverseswitchintheNEUTRALposition.Chockthe

wheelswhenservicingthevehicle.

•Disconnectchargerplugbeforeservicingvehicle.

•PlaceTow/RunswitchintheTOWpositionbeforedisconnectingorconnectingthebatteries.Failureto

heedthiswarningcouldresultinabatteryexplosionorseverepersonalinjury.

•Toavoidunintentionallystartinganelectricvehicle,disconnectthebatteriesanddischargethe

controller.SeeDisconnectingtheBatteries–ElectricVehiclesonpage1-3.

•Donotleavechildrenunattendedonvehicle.

DISABLINGTHEVEHICLE

1.Settheparkbrake.

2.TurnthekeyswitchOFFandremovethekey.

3.PlacetheForward/ReversecontrolintheNEUTRALposition.

4.Inaddition,chockthewheelsifservicingorrepairingthevehicle.

Page1-22009-2011ElectricPrecedentMaintenanceandServiceManual

SAFETYGeneralWarnings1

DISCONNECTINGTHEBATTERIES–ELECTRICVEHICLES

1.Disablethevehicle.SeeDisablingtheVehicleonpage1-2.

2.PlaceTow/RunswitchintheTOWpositionbeforedisconnectingorconnectingthebatteries.Failuretoheed

thiswarningcouldresultinabatteryexplosionorseverepersonalinjury.

3.Disconnectthebatteries,negative(–)cablerst,asshown(Figure1-1)or(Figure1-2).

4.Afterdisconnectingthebatteries,wait90secondsforthecontrollercapacitorstodischarge.

(+)

POS

NEG

POS

NEG

POS

NEG

(–)

(Viewedfromdriversideofvehicle)

1.PlaceTOW/RUNSwitchinTOWbeforedisconnectingorconnecting

batterycables.

2.Removenegativebatterycable.

3.Removepositivebatterycable.

Connectbatterycablesinreverseorder.

TOW

RUN

(–)

(+)

(Viewedfromdriversideofvehicle)

1.PlaceTOW/RUNSwitchinTOWbeforedisconnectingorconnecting

batterycables.

2.Removenegativebatterycable.

3.Removepositivebatterycable.

Connectbatterycablesinreverseorder.

422

Figure1-1BatteryCableRemoval–4x12-VoltBattery

Conguration

49A

Figure1-2BatteryCableRemoval–6x8-VoltBattery

Conguration

CONNECTINGTHEBATTERIES–ELECTRICVEHICLES

1.EnsuretheTow/RunswitchisintheTOWposition.

2.Connectthebatterycables,positive(+)cablerst.

3.Tightenbatteryterminalsto110in-lb(12.4N·m).

4.CoatterminalswithBatteryTerminalProtectorSpray(P/N1014305)tominimizecorrosion.

RECYCLINGLEAD-ACIDBATTERIES

WARNING

•Lead-acidbatteriescontainlead(Pb),othermetals,acidsandothercompounds.Ifimproperlyhandled,

theycancontaminatebothwaterandsoil,causingenvironmentaldamageandpersonalinjury.

Lead-acidbatteriesareidentiedbythesymbolshownbelowandshouldbeproperlyrecycled(Figure1-3).They

cannotbedisposedasmunicipalwasteandmustbecollectedseparately.Responsibilityforenvironmentalprotection

2009-2011ElectricPrecedentMaintenanceandServiceManualPage1-3

1GeneralWarningsSAFETY

mustbeshared,notonlybythemanufacturersofthebatteries,butbypeoplewhousethebatteriesaswell.Please

contactyournearestClubCardealerordistributorforinformationonhowtoproperlyrecycleyourbatteries.

1403

Figure1-3DisposeofLead-acidBatteriesProperly

INTERNATIONALSAFETYSYMBOLSONBATTERIES

Anyoneusing,repairing,orservicingthevehiclemustunderstandandheedthesafetysymbolsonthevehiclebattery

orbatteries.

123456

1.Shieldeyes.3.Nosmoking,noopenames,nosparks.5.Batteryacidhazard.

2.Readandfollowoperatinginstructions.4.Keepawayfromchildren.6.Explosivegashazard.

RefertoGeneralWarningsformoreinformation.

1642

Figure1-4InternationalSafetySymbolsonBatteries

Page1-42009-2011ElectricPrecedentMaintenanceandServiceManual

SECTION2–VEHICLESPECIFICATIONS2

SPECIFICATIONS

TWO-

PASSENGER

ELECTRIC

VEHICLE

FOUR-

PASSENGER

ELECTRIC

VEHICLE

POWERSOURCE

Drivemotor:Directdrive,48voltsDC,shunt-wound,3.1hp••

Transaxle:Doublereductionhelicalgearwith12.3:1directdriveaxle••

Electricalsystem:48voltsDC,reducedspeedreverse••

Batteries:Highcapacity,deepcycle••

Charger:Automatic,48-volt;ULandCSAlisted••

STEERING/SUSPENSION/BRAKES

Steering:Self-adjustingrackandpinion••

Suspension:Frontandreartaperedmono-leafspringswithdualhydraulicshocks••

Brakes:Dualrearwheelself-adjustingbrakeswithcastirondrumsandsinglebrakepedalwith

automatic-releaseparkbrake••

BODY/CHASSIS

Frame/Chassis:Aluminumandcomposite••

Bodynish:High-glossmolded-incolor••

Tires:18x8.5–8tubeless,4plyrated••

DIMENSIONS/WEIGHT

Overalllength91.5in.(232cm)104in.(264cm)

Overallwidth47.25in.

(120cm)

47.25in.

(120cm)

Overallheight(withcanopy)68.5in.(174cm)71in.(180cm)

Overallheight(atsteeringwheel)48.0in.(122cm)48.0in.(122cm)

Wheelbase65.5in.(166cm)65.5in.(166cm)

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

Frontwheeltread34.5in.(88cm)34.5in.(88cm)

Rearwheeltread38.6in.(98cm)38.6in.(98cm)

Weight(standardelectricvehiclewithcanopy,withbatteries)

Forvehicleswithsix8-voltbatteries,add54lb.(24.5kg).855lb.(388kg)970lb.(440kg)

Forwardspeed12-15mph(19-24km/h)

Curbclearancecircle(diameter)17ft-4in.(528cm)17ft-4in.(528cm)

Standardseatingcapacity24

LIQUIDCAPACITIES

Transaxle22oz.

(.67liters)

22oz.

(.67liters)

TABLECONTINUEDONNEXTPAGE

2009-2011ElectricPrecedentMaintenanceandServiceManualPage2-1

2GeneralWarningsVEHICLESPECIFICATIONS

SPECIFICATIONS

TWO-

PASSENGER

ELECTRIC

VEHICLE

FOUR-

PASSENGER

ELECTRIC

VEHICLE

TIREPRESSURE

Frontandrear18-20psi(1.24-1.38

bars)

18-20psi(1.24-1.38

bars)

Page2-22009-2011ElectricPrecedentMaintenanceandServiceManual

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