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Club Car 2005 Precedent, Maintenance And Service

The Club Car 2005 Precedent is a reliable golf cart featuring advanced technology. Ensure its longevity with the Maintenance And Service manual available for free download at manualshive.com. This comprehensive manual will help you properly care for your investment, maximizing its performance and lifespan. Download your manual today!

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Page viii

2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual

Charging a Battery Pack that has Low Voltage ................................................................................

13-12

SECTION 14 – BATTERY CHARGER

SECTION 15A – MOTOR (MODEL 5BC59JBS6365)

General Information  .........................................................................................................................

15a-1

Motor Identification ...........................................................................................................................

15a-1

External Motor Testing  .....................................................................................................................

15a-1

Motor ................................................................................................................................................

15a-3

Motor Component Testing and Inspection  .......................................................................................

15a-5

Armature ......................................................................................................................................

15a-5

Field Windings Inspection  ............................................................................................................

15a-6

Motor Components .......................................................................................................................

15a-7

Bearing Inspection  .......................................................................................................................

15a-7

Bearing Removal ..........................................................................................................................

15a-9

Bearing Installation .......................................................................................................................

15a-9

Speed Sensor Magnet Inspection  ................................................................................................

15a-9

Speed Sensor Magnet Removal  ..................................................................................................

15a-9

Speed Sensor Magnet Installation  ...............................................................................................

15a-9

Reconditioning the Motor  .................................................................................................................

15a-9

Motor Assembly  ............................................................................................................................... 15a-10

Motor Installation .............................................................................................................................. 15a-12

Motor Speed Sensor  ........................................................................................................................ 15a-15

SECTION 15B – MOTOR (MODEL EJ4-4001)

General Information  .........................................................................................................................

15b-1

Motor Identification ...........................................................................................................................

15b-1

External Motor Testing  .....................................................................................................................

15b-1

Motor ................................................................................................................................................

15b-2

Motor Removal  .............................................................................................................................

15b-2

Motor Disassembly .......................................................................................................................

15b-4

Motor Component Testing and Inspection  .......................................................................................

15b-6

Armature Inspection and Testing  .................................................................................................

15b-6

Motor Frame and Field Windings Inspection ................................................................................

15b-8

Motor Brush, Spring, and Terminal Insulator Inspection  ..............................................................

15b-8

Reconditioning the Motor  ................................................................................................................. 15b-11

Motor Assembly  ............................................................................................................................... 15b-11

Summary of Contents for 2005 Precedent

Page 1: ...2005 Maintenance And Service Manual No 102680401 Edition Code 0205C0306B IQ System Electric Vehicles...

Page 2: ......

Page 3: ...advises that all repairs and or service be performed by an authorized Club Car distributor dealer representative or by a Club Car factory trained technician It is the policy of Club Car Inc to assist...

Page 4: ...cles and other products These improvements may affect servicing procedures Any modification and or significant change in specifications or proce dures will be forwarded to all Club Car dealers and wil...

Page 5: ...Electric Vehicle to Service 3 3 SECTION 4 BODY AND TRIM Cleaning the Vehicle 4 1 Seat 4 1 Front and Rear Body Repair 4 2 Stress Lines or Streaks 4 2 Minor Impact Damage Deformations 4 2 Minor Scratche...

Page 6: ...nger 4 15 Canopy Two Passenger 4 16 Two Passenger Canopy Removal 4 16 Two Passenger Canopy Installation 4 18 Canopy Four Passenger 4 20 Four Passenger Canopy Removal 4 20 Four Passenger Canopy Install...

Page 7: ...lation 7 9 Front Suspension 7 10 Lubrication 7 10 Wheel Alignment 7 10 Front Suspension Components 7 12 Tie Rod End Removal 7 12 Tie Rod Installation 7 12 Leaf Spring Removal 7 13 Leaf Spring Installa...

Page 8: ...Passenger Vehicles 9 4 Leaf Spring Removal Four Passenger Vehicles 9 4 Leaf Spring Installation Four Passenger Vehicles 9 6 SECTION 10 PERIODIC MAINTENANCE General Information 10 1 Periodic Service Sc...

Page 9: ...ptacle 12 13 SECTION 13 BATTERIES General Information 13 1 Battery Replacement 13 1 Battery Care 13 2 Preventive Maintenance 13 2 Self Discharge 13 3 Electrolyte Level 13 3 Mineral Content 13 4 Vibrat...

Page 10: ...earing Installation 15a 9 Speed Sensor Magnet Inspection 15a 9 Speed Sensor Magnet Removal 15a 9 Speed Sensor Magnet Installation 15a 9 Reconditioning the Motor 15a 9 Motor Assembly 15a 10 Motor Insta...

Page 11: ...SECTION 16 TRANSAXLE TYPE G Lubrication 16 1 Axle Bearing and Shaft 16 1 Axle Shaft 16 1 Axle Bearing 16 4 Transaxle 16 5 Transaxle Removal 16 5 Transaxle Disassembly Inspection and Assembly 16 7 Tra...

Page 12: ......

Page 13: ...A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result in minor personal injury CAUTION A CAUTION without the safety alert symbol indicates a potentially hazard...

Page 14: ...eyond factory specifications could result in severe personal injury or death Check the vehicle for proper location of all vehicle safety and operation decals and make sure they are in place and are ea...

Page 15: ...neutral and reduced speed reverse 11 8 1 for ward 17 1 1 reverse Torque converter Automatic variable speed dry type Electrical system 12 volt 500 cca at 0 F 17 8 C 650 at 32 F 0 C 105 minute reserve c...

Page 16: ...15 mph 19 24 km h Curb clearance circle diameter 17 ft 4in 528 cm 17 ft 4 in 528 cm Standard seating capacity 2 4 LIQUID CAPACITIES Transaxle 22 oz 67 liters 22 oz 67 liters Engine crankcase without...

Page 17: ...tion to features specific to their vehicle s Refer to the owner s manual provided with the vehicle for information on the following topics Pre Operation and Daily Safety Checklist Controls and Indicat...

Page 18: ...o be enforced The safety committee should include all these items and such others as the committee feels necessary or appropriate Warning signs available from Club Car are listed below STORAGE See Gen...

Page 19: ...e 7 Do not engage the park brake Chock the wheels to prevent the vehicle from rolling 8 Keep batteries fully charged during storage Leave chargers plugged in during storage The onboard computer will a...

Page 20: ...3...

Page 21: ...osote paint or chewing gum should be removed immediately to prevent possible stains See following CAUTION and NOTE CAUTION Use of leveling or rubbing compounds will permanently dull finish of vehicle...

Page 22: ...resulting from minor impact damage 1 Hold a heat gun 12 inches 30 cm away from the affected area with the gun on its lowest heat setting 2 Periodically remove the heat gun and bend the body using a pu...

Page 23: ...D TRIM Front and Rear Body Repair 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 4 3 4 Figure 4 1 Front Body 3 8 TYPICAL 5 PLACES 2 1 5 6 7 TYPICAL 4 PLACES TYPICAL 5 P...

Page 24: ...ont beauty panel 3 over brow 5 Tabs on the forward edge of the front beauty panel should fit into slots between the fascia and the brow 4 Position brow cap 1 to cover the edge of both the brow 5 and t...

Page 25: ...ent IQ System Electric Golf Car Maintenance and Service Manual Page 4 5 4 Figure 4 2 Bracket and Front Bumper Figure 4 3 Instrument Panel UNDERBODY FRONT SUSPENSION 2 1 2 3 4 5 1 2 3 4 7 6 5 TYPICAL 2...

Page 26: ...tion the instrument panel 3 on the dash assembly Make sure tabs on upper edge properly engage with the corresponding slots on the dash assembly Ensure that there are no wires exposed or pinched during...

Page 27: ...ICK PLATE AND CHARGER RECEPTACLE BEZEL See General Warnings Section 1 Page 1 1 KICK PLATE AND CHARGER RECEPTACLE BEZEL REMOVAL 1 If charger bezel 4 requires removal use charger bezel tool CCI P N 1025...

Page 28: ...ural Accessory Module SAM includes two threaded inserts on both the driver side and the pas senger side Figure 4 6 Page 4 8 These inserts serve as common attachment points for various accessor ries Ac...

Page 29: ...senger Vehicles 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 4 9 4 Figure 4 7 Backrest and SAM 10 TYPICAL 2 PLACES 6 7 8 5 12 9 9 12 11 2 3 4 1 TYPICAL 2 PLACES TYPIC...

Page 30: ...ving two plastic barrel connectors 9 and one screw 12 3 Bag strap buckles 7 may be snapped out of bag hoop 6 Bag Rack Installation Installation is the reverse of removal Tighten screw 12 to 4 8 ft lb...

Page 31: ...Electric Golf Car Maintenance and Service Manual Page 4 11 4 Figure 4 8 Rear Body Components 13 16 TYPICAL 4 PLACES 14 5 4 5 7 6 8 11 11 10 10 12 15 BODY CLIPS RED WHITE BLUE 2 3 1 TWO PASSENGER VEHIC...

Page 32: ...derbody Removal 1 Remove four screws 5 attaching the rear underbody 4 to vehicle Figure 4 8 Page 4 11 2 Remove two screws 18 and washers 23 that attach the underbody to the two liners 8 and 9 3 Lift t...

Page 33: ...hip restraints 6 and remove the hip restraints from the vehicle Figure 4 9 Page 4 13 2 Remove the screws 5 and bolts 4 from the seat support 3 and remove the seat support from the vehi cle Seat Suppor...

Page 34: ...d remove the hip restraints from the vehicle Figure 4 9 Page 4 13 4 Remove the four bolts 2 securing the foot deck 1 to the vehicle frame Figure 4 10 Page 4 14 Foot Deck Installation 1 Install foot re...

Page 35: ...rt Removal on page 4 13 2 Remove four screws 13 attaching the rear beauty panel 12 to the fuel bucket Figure 4 8 Page 4 11 3 Remove two screws 14 and remove the Forward Reverse switch housing 15 from...

Page 36: ...ear underbody 4 until the front portion slides out from beneath the front under body Remove the rear underbody from the vehicle Rear Underbody Installation 1 Install rear underbody 4 on the vehicle Fi...

Page 37: ...BODY AND TRIM Canopy Two Passenger 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 4 17 4 Figure 4 12 Precedent Two Passenger Canopy 13 14 4 5 3 9 11 7 12 6 10 1 8...

Page 38: ...o bolts 6 through the basket wall and into each support The bolts are color coded with blue thread lock Finger tighten the bolts to avoid cross threading the threads in the supports See following CAUT...

Page 39: ...Service Manual Page 4 19 4 Figure 4 13 Precedent Four Passenger Canopy TYPICAL 2 PLACES 5 4 2 TYPICAL 2 PLACES 1 6 13 9 6 11 9 1 10 12 14 16 16 TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPI...

Page 40: ...13 Page 4 19 The lower profile of each support follows the profile of the vehicle If the supports are placed on the wrong side of the vehicle they will not follow the vehicle s profile 1 2 Align the...

Page 41: ...GROUP REMOVAL 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Remove screws 1 Pull floor mat retainer 3 away from...

Page 42: ...BRAKE PEDAL GROUP Pedal Group Page 5 2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual 5 Figure 5 2 Pedal Group 2 TYPICAL 2 PLACES 1 TYPICAL 2 PLACES 3 ELECTRICAL CONNECTION...

Page 43: ...for the Precedent electric vehicle includes a Motor Controller Output Regulator MCOR mounted on the side of the pedal group The MCOR detects the position of the GO pedal and sends a corre sponding vol...

Page 44: ...secured by two crosspins Figure 5 4 Page 5 5 The assembly is replaced as a unit The replacement unit includes a pin that keeps the spring compressed so it can be installed in the pedal group Replace t...

Page 45: ...OR AND BRAKE PEDAL GROUP Pedal Group 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 5 5 5 Figure 5 4 Brake Pedal 1 2 3 4 5 7 8 6 10 7 9 OPPOSITE SIDE VIEW 11 12 Typical...

Page 46: ...driver side screws 2 to 12 ft lb 16 3 N m Tighten passenger side screws 1 to 5 ft lb 6 8 N m 4 Use the turnbuckle 6 to connect the rod from the pedal group to the brake actuator rod Ensure the ends of...

Page 47: ...To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Place chocks at the front wheels Loosen but do not remove lug nuts on rear wheels and lift the rear of the vehicle with a cha...

Page 48: ...release the shoes from the backing plate allowing them to pivot away from the inside of the brake drum which should then allow the brake drum to be pulled free After completing step 8 skip step 9 NOT...

Page 49: ...al 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 6 3 6 Figure 6 4 Self adjusting Wheel Brake Assembly 10 TYPICAL 4 PLACES 1 8 6 9 4 3 2 13 12 6 5 7 TYPICAL 2 PLACES 7...

Page 50: ...ION The brake shoes are under pressure and can release suddenly when brake shoe retainers are removed 10 Grasp both brake shoes and pull them together with the springs out of the brake assembly as sho...

Page 51: ...g could cause diminished brake performance possibly resulting in property damage or severe personal injury 4 Use a small brush to carefully apply a light coat of white lithium NLGI 2 grease Dow Cornin...

Page 52: ...nge marked 17T should be facing out and be visible On the driver side the 17L on the leading shoe should be facing out and be visible When installed on the backing plate the leading shoe stamped 17L i...

Page 53: ...pward until it stops Figure 6 17 Page 6 7 Remove the screw driver 7 Install the rear axle onto the transaxle See following NOTE NOTE There is a LEFT and RIGHT side axle The splined portions on the axl...

Page 54: ...rly seated in groove If ring is not properly installed the axle assembly will separate from the transaxle and damage the axle assembly and other components Loss of vehicle control could result in seve...

Page 55: ...loor mat sides are beneath the sill 3 Tighten screws 1 to 53 in lb 6 N m See Figure 5 1 Section 5 Page 5 1 BRAKE CLUSTER REMOVAL AND INSTALLATION See General Warnings Section 1 Page 1 1 See also Warni...

Page 56: ...of the axle shaft into the axle tube Be careful not to damage the seal on the inside of the axle tube hub Advance the shaft through to the bearing on the shaft and rotate it to align the shaft spline...

Page 57: ...from the turnbuckle 5 Loosen turnbuckle 2 until the bolt 5 is free of the turnbuckle 6 Rotate the bolt 5 and equalizer bracket 4 to the upright position then slip the cable heads out of the bracket 7...

Page 58: ...bracket 4 in the upright position and slip the cable head through the hole on top of the bracket Pivot the equalizer to the horizontal position to capture the cable heads in the equalizer 3 Insert the...

Page 59: ...ng screws 8 Figure 7 3 Page 7 3 3 Remove the scorecard holder plate 1 4 Match mark the steering wheel 7 and steering column shaft 9 so when the steering wheel is removed it can be placed back in exact...

Page 60: ...ks placed on the wheel and steering column in step 4 above Figure 7 3 Page 7 3 2 Install the steering wheel bolt 6 and tighten to 13 ft lb 17 6 N m 3 Install the scorecard plate 1 4 If required instal...

Page 61: ...System Electric Golf Car Maintenance and Service Manual Page 7 3 7 Figure 7 3 Steering Column 1 4 5 6 3 2 7 9 11 13 10 12 8 NOT REQUIRED FOR SOME SCORECARD HOLDERS APPEARANCE OF SCORECARD HOLDER MAY...

Page 62: ...Leave bolt 11 loose until steering column is mounted to frame in step 3 Figure 7 3 Page 7 3 3 Align the holes in the steering column mounting bracket with holes in the vehicle frame Secure column to f...

Page 63: ...and slide off both of the dust seal bellows 9 from ball joints 8 4 Remove rack screw nut 14 rack guide screw 13 rack guide pressure spring 15 and the rack guide 16 5 Remove the universal joint assembl...

Page 64: ...NT SUSPENSION Rack and Pinion Page 7 6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual 7 Figure 7 5 Steering Gear 1 2 4 3 5 6 7 18 8 8 17 21 21 16 15 14 13 9 9 10 10 11 11 12...

Page 65: ...Figure 7 9 Page 7 7 11 Inspect the bushing 7 and needle bearing 6 for excessive wear If wear is excessive replace the entire assembly Figure 7 5 Page 7 6 12 Inspect the ball joints 8 for wear If one...

Page 66: ...7 5 Page 7 6 7 Install the ball joints 8 onto the rack 18 by securing the rack in a vise using wood blocks between the rack and the jaws of the vise to protect the rack from damage Tighten the ball j...

Page 67: ...position the assembly over the mounting holes and slide the universal joint over the square end of the steering column 4 Install three screws to secure the assembly to the vehicle Tighten screws to 22...

Page 68: ...necessary Camber Adjustment 1 Check each front wheel with a framing square At the floor or ground there should be an equal amount of space between each tire and the framing square Figure 7 14 Page 7 1...

Page 69: ...ks should be even with the bottom surfaces of the vehicle frame 3 Measure the distance between the marks on the rear facing surfaces of the tires and then roll the vehicle forward one and one half whe...

Page 70: ...teering wheel should be at the center of its travel There should be equal travel to the left and right FRONT SUSPENSION COMPONENTS See General Warnings Section 1 Page 1 1 TIE ROD END REMOVAL 1 Loosen...

Page 71: ...ghtening lug nuts using a crisscross pattern to 55 ft lb 74 6 N m 6 Adjust camber and toe in See Wheel Alignment on page 7 10 KINGPIN AND STEERING SPINDLE REMOVAL 1 Remove the front hub See Front Hub...

Page 72: ...ge 7 15 4 Remove bolts 11 and 19 5 Remove the control arm 6 6 Inspect the bushings 7 and sleeves 8 and 9 in the control arm and replace them if necessary CONTROL ARM INSTALLATION 1 Install the control...

Page 73: ...PENSION Front Suspension Components 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 7 15 7 Figure 7 18 Upper Front Suspension Assembly 4 8 11 10 2 3 5 6 7 9 6 4 3 1 2 14...

Page 74: ...ENSION Front Suspension Components Page 7 16 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual 7 Figure 7 19 Lower Front Suspension Assembly 1 3 4 2 5 4 6 7 8 9 10 11 12 13 14...

Page 75: ...16 3 Slide the hub assembly 9 off of the spindle shaft 3 4 Lightly sand spindle shaft to clean away any light rust 5 Inspect the surface of the spindle shaft for surface damage It should be clean and...

Page 76: ...7...

Page 77: ...and adjusted WARNING Tires affect vehicle handling When selecting a replacement tire use only original equipment or comparable tires WHEELS See General Warnings Section 1 Page 1 1 WHEEL REMOVAL 1 Sli...

Page 78: ...ge of the wheel rim Figure 8 1 Page 8 2 Detail B CAUTION To avoid damage to the tire do not use excessive force when starting the bead over the edge of the rim 3 3 When top bead is free of the rim pul...

Page 79: ...ire mounting lubricant soap and water solution to both tire beads and rim flanges 4 Install the tire on the rim from the valve stem side If there is no tire machine available use a rubber mallet and t...

Page 80: ...WHEELS AND TIRES Tires Page 8 4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual 8 Figure 8 2 Inflate Tire...

Page 81: ...the nut 5 cup washer 9 and rubber bushings 10 from the stem at the top of the shock absorber 3 Remove the nut 5 cup washer 9 and rubber bushings 10 from lower mounting stem 4 Compress the shock absor...

Page 82: ...IQ System Electric Golf Car Maintenance and Service Manual 9 Figure 9 1 Rear Suspension Assembly and Mounting Two Passenger Vehicles 16 TYPICAL 2 PLACES 9 10 10 9 5 6 8 7 4 3 4 17 1 14 4 2 4 2 11 3 4...

Page 83: ...compressing them 3 Remove the tire and wheel assembly on the side from which the spring is to be removed 4 Remove the bow tie locking pin 1 and the clevis pin 2 at the brake lever and brake cable conn...

Page 84: ...b 454 kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remai...

Page 85: ...Maintenance and Service Manual Page 9 5 9 Figure 9 4 Rear Suspension Assembly and Mounting Four Passenger Vehicles 15 26 27 REAR OF VEHICLE 9 10 10 9 5 4 3 4 11 3 4 12 20 13 15 2 17 17 REF REF TYPICAL...

Page 86: ...ER VEHICLES 1 To install the springs reverse the removal procedure See following CAUTION CAUTION When positioning the spring on the transaxle be sure to insert the locating bolt on the spring in the l...

Page 87: ...il it is properly repaired This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions Contact your local Club Car distributor dealer to perform all re...

Page 88: ...y terminals Tires Check air pressure and adjust if necessary See Section 2 Vehicle Specifications General vehicle Thoroughly wash vehicle including the underside Semiannual service by trained technici...

Page 89: ...n every 50 hours of operation or 100 rounds of golf Charger receptacle WD 40 Brake system per maintenance and service manual Dry Moly Lube CCI P N 1012151 white lithium grease NLGI 2 Front suspension...

Page 90: ...10...

Page 91: ...ain conditions a shunt wound motor also has the ability to act as an electri cal brake to slow the vehicle There are three features of the IQ electrical system which will activate the motor braking fu...

Page 92: ...H SONIC WELD PIN 9 GRAY AUX PIN 5 LT BLUE POWER DOWN PIN 4 OPEN PIN 3 PURPLE TO LOW SIDE OF POTENTIOMETER PIN 2 YELLOW TO SLIDER OF POTENTIOMETER PIN 1 WHT BLK TO HIGH SIDE OF POTENTIOMETER 8 16 9 1 X...

Page 93: ...TE 18 WHITE 6 PIN GROUP CONNECTOR 10 BLACK 16 BLUE 16 BLUE ON BOARD COMPUTER NOTE SOME WIRING COMPONENTS SHOWN ARE OPTIONAL ACCESSORIES 10 BLACK 6 BLACK 18 YELLOW 18 RED 18 BROWN WHITE 10 BLACK 10 RED...

Page 94: ...OR HORN SONIC WELD 9 PIN CONNECTOR 16 BROWN WHITE 16 YELLOW 16 WHITE 16 BLUE WHITE 16 RED 16 GREEN 16 ORANGE 16 BLACK 16 BROWN WHITE 16 YELLOW 16 WHITE 16 BLUE WHITE 16 RED 16 GREEN 16 ORANGE 16 BLACK...

Page 95: ...BROWN 16 BLACK WHITE 16 WHITE 18 BLUE WHITE 18 ORANGE 16 BLUE 16 GRN WHT 12 BLUE 12 BLACK 12 BLACK 16 BLACK WHITE 14 YELLOW 14 YELLOW 16 BROWN 16 BROWN WHITE 16 YELLOW 16 WHITE 16 BLUE WHITE 16 RED 16...

Page 96: ...18 BROWN WHITE 18 BLACK 18 GREEN 18 YELLOW 18 RED 18 ORANGE WHITE 18 BLACK YELLOW 16 GREEN RED 16 BLUE 18 RED 1 6 G R E E N 18 18 BROWN WHITE 18 ORANGE 18 PINK WARNING LIGHT REVERSE BUZZER PROGRAMMER...

Page 97: ...h is used to change the direction of travel The vehicle will not move until the accelerator is released and pressed again When this situation arises a HPD fault is recorded by the speed controller and...

Page 98: ...ses are OFF when the vehicle is in motion or Diagnostic Menu SPEED SENSOR fault code Loose or disconnected motor speed sensor or broken wire Repair and or connect the three pin connector to the motor...

Page 99: ...0 Diagnostic Menu THROTTLE FAULT 1 fault code Loose or disconnected three pin connector at the MCOR or broken wire Repair and or connect the three pin connector to the MCOR Loose or disconnected 16 pi...

Page 100: ...ully remove foot from accelerator pedal before turning key switch to the ON position or changing the selected direction with the Forward Reverse switch Diagnostic Menu LOW BATTERY fault code Batteries...

Page 101: ...it Switch Circuit on page 11 20 Failed MCOR Test Procedure 8 Key Switch and MCOR Limit Switch Circuit on page 11 20 See also Test Procedure 4 MCOR Voltage on page 11 17 Forward Reverse rocker switch T...

Page 102: ...el Brake Assemblies Tires under inflated or flat tires See Section 8 Wheels and Tires Vehicle operates but motor braking function does not Wiring improperly wired Check vehicle wiring See Wiring Diagr...

Page 103: ...dule cover must be removed to gain access to the various components that are mounted on the component mounting plate Remove screw 1 and remove cover 2 Figure 11 6 Page 11 13 See following WARNING WARN...

Page 104: ...CHECK See General Warnings Section 1 Page 1 1 NOTE The batteries must be properly maintained and fully charged in order to perform the following test procedures Battery maintenance procedures includi...

Page 105: ...e reading is 48 50 volts proceed to Test Procedure 3 Solenoid Activating Coil on page 11 16 3 Place insulation piercing probe on the light blue 18 gauge wire at a point between OBC six pin connector a...

Page 106: ...no 4 negative post and place the red probe with insulation piercing probe on the red 18 gauge wire harness side of six pin connector Multimeter should indicate 48 volts If voltage is correct check co...

Page 107: ...rear of the vehicle with a chain hoist or floor jack Position jack stands under the frame rails just forward of each spring mount See WARNING Lift only one end in General Warnings Section 1 Page 1 2...

Page 108: ...hould indicate between 5 67k ohms and 7 43k ohms 8 6 Using a multimeter set for 20k ohms connect the red probe of the multimeter to the yellow wire at the MCOR three pin connector with an insulation p...

Page 109: ...sition and proceed to step 5 otherwise perform the following procedure Tow Run Switch Test without the IQDM Handset 5 With the IQDM still connected to the vehicle place the Tow Run Switch in the TOW p...

Page 110: ...n of the batteries When the discharge machine is ON it places the battery pack under load and many times can help determine if one or more batteries in the set have failed Testing battery voltage whil...

Page 111: ...rcuit Test without the IQDM Handset 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 2 Place chocks at the front wheel...

Page 112: ...he green wire where it connects to the MCOR With the Tow Run switch in the RUN position the key switch ON the Forward Reverse rocker switch in NEUTRAL and the accelerator pedal pressed the reading sho...

Page 113: ...lack probe into pin 3 purple wire of the 16 pin connector Figure 11 10 Page 11 24 CAUTION Do not fully insert probes into the 16 pin plug Doing so can result in a poor connection 5 With the accelerato...

Page 114: ...point for the solenoid lockout circuit from the onboard computer to the speed controller 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning...

Page 115: ...d to the vehicle 13 If any other reading is obtained check the following items Continuity of the wires in the wire harness Onboard computer for proper operation See Test Procedure 11 Onboard Computer...

Page 116: ...lowly press the accelerator pedal and hold the pedal at approximately 20 of full travel 9 After a short delay the onboard computer should power up come out of sleep mode 10 The multimeter should indic...

Page 117: ...ntroller 4 Place a jumper wire with an alligator clip between the B terminal of the speed controller use alligator clip for this connection and pin 7 orange white wire of the 16 pin connector Figure 1...

Page 118: ...14 Page 11 29 CAUTION Do not fully insert probes into the 16 pin plug Doing so can result in a poor connection 5 Place the Tow Run switch in the TOW position and connect the battery cables positive ca...

Page 119: ...WARNING Lift only one end in General Warnings Section 1 Page 1 2 3 Disconnect the 16 pin connector at the speed controller 4 Using a multimeter set for 200 volts DC insert the red probe of the multime...

Page 120: ...cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 2 Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or flo...

Page 121: ...he speed controller The speed controller activates the solenoid coil by providing a ground to the solenoid coil at the appropriate time 1 Disconnect the battery cables as instructed See WARNING To avo...

Page 122: ...SCR located inside the onboard computer acts as a switch on the negative side of the circuit This allows the onboard computer OBC to control the battery charging current Use the following procedure to...

Page 123: ...DC cord into the vehicle s charger receptacle The voltage reading should drop to approximately 4 0 volts before the charger relay clicks on 3 When the charger relay is activated the reading should ri...

Page 124: ...socket in the three pin connector The voltage reading should be 48 to 50 volts full battery voltage 3 2 If the reading is zero volts check the continuity of the black white wire from the 16 pin connec...

Page 125: ...h a chain hoist or floor jack Position jack stands under the frame rails just forward of each spring mount See WARNING Lift only one end in General Warnings Section 1 Page 1 2 2 Disconnect the battery...

Page 126: ...n The IQDM should indicate that REVERSE INPUT is ON If the IQDM indicates any other reading check vehicle wiring See Wiring Diagrams on page 11 2 Also check the 16 pin connector at the speed controlle...

Page 127: ...he orange white wire terminal end that was disconnected from the reverse buzzer and place the red probe on battery no 1 positive post The reading should be approximately 48 volts full battery voltage...

Page 128: ...lug 6 Install the wedgelock in the six pin connector housing and reconnect the six pin connector plug Place the Tow Run switch in the RUN position and the battery light should illuminate If the light...

Page 129: ...ged and the first time a set of batteries is charged after the batteries have been disconnected and reconnected A problem may exist if persistent DVDT readings are obtained 4 Indicates the last charge...

Page 130: ...e button The value for F3 will be displayed To view F4 press and hold the button on the CDM until Func 4 appears in the display window Release the button The value for F4 will be displayed NOTE The va...

Page 131: ...ction 11 Page 11 20 Key Switch Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Remove the instrument panel...

Page 132: ...e 12 2 Page 12 2 2 Connect the blue and green wires to the key switch terminals Either orientation is correct See Wiring Diagrams Section 11 Page 11 2 3 Install the instrument panel 3 1 Connect the el...

Page 133: ...wo retaining tabs 11 and remove the light from the center dash Figure 12 3 Page 12 3 Battery Warning Light Installation 1 Install in reverse order of removal 2 Place the Tow Run switch in the TOW posi...

Page 134: ...n position on the body and install the two screws 2 Tighten to 20 in lb 2 3 N m 4 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten battery termi...

Page 135: ...5 Page 12 5 3 Hold battery wire out of way and lift cover 2 off the vehicle Electronics Module Cover Installation 1 Hold battery wire out of way and place cover 2 over the electronics module 2 Instal...

Page 136: ...switch boot hex nut 1 Figure 12 6 Page 12 6 4 Remove Tow Run switch 2 from bracket 5 Disconnect the two wires 3 and remove switch Tow Run Switch Installation 1 Installation is reverse of removal Make...

Page 137: ...o pin and three pin connectors 1 from the MCOR 2 Figure 12 7 Page 12 7 4 Remove the hex head screws 3 connecting the MCOR to the pedal group MCOR Installation 1 Secure the MCOR 2 to the pedal group wi...

Page 138: ...connect the 18 gauge pink and orange white wires from reverse buzzer 4 Remove the two screws from the reverse buzzer Remove the reverse buzzer from the dash panel Reverse Buzzer Installation 1 Install...

Page 139: ...12 9 12 Figure 12 9 Electronics Module Removal S 2 S 1 M B B S 2 S 1 4 PIN CONNECTOR TO MOTOR 16 PIN CONNECTOR POWER CONNECTIONS BLACK WIRE TO CONTROLLER OBC FROM DRIVER SIDE GRAY WIRE TO CHARGER REC...

Page 140: ...Lift the electronics module from the vehicle See following WARNING WARNING Shorting of battery terminals can cause personal injury or death Do not place component mounting plate directly on top of ba...

Page 141: ...the controller to the component mounting plate and tighten to 5 5 ft lb 7 5 N m Figure 12 10 Page 12 12 2 Install electronic module assembly in the vehicle See Electronics Module Installation on page...

Page 142: ...s from solenoid 4 Loosen both solenoid mounting screws 2 Figure 12 10 Page 12 12 5 Rotate solenoid up in front and slide off of the component mounting plate Solenoid Installation 1 Mount solenoid onto...

Page 143: ...ge 12 9 Make sure all connections are fully seated and boot on gray sense lead is properly seated 3 Install electronics module cover See Electronics Module Cover Installation on page 12 5 4 Place the...

Page 144: ...ptacle Installation 1 Insert the wires through the hole in the bucket Figure 12 11 Page 12 14 2 Insert receptacle 2 into bucket 3 Install the three screws 1 that secure the receptacle to the bucket Ti...

Page 145: ...r vehicle are different from those supplied with an automobile The outward appearance of these two batteries is similar but the operating characteristics are very different The Club Car electric vehic...

Page 146: ...not so tight as to crack or buckle battery case Tighten to 97 4 in lb 11 N m alternating between hold down bolts 6 Install wires in proper sequence Figure 13 1 Page 13 2 Install black wire to negative...

Page 147: ...discharge batteries should always be kept clean Hot weather also has an effect on a battery s self discharge rate The higher the temperature the quicker a set of batteries will discharge In hotter cl...

Page 148: ...of the battery It may also cause acid to leak out of the vent caps and corrosion to build up on surrounding metal parts The acid which is lost reduces the capacity of the battery and cannot be replac...

Page 149: ...o limit the use of any vehicle with new batteries for at least the first four weeks and then grad ually increase their range INCOMING AC SERVICE Make sure the incoming AC line service is sufficient If...

Page 150: ...e 9 3V and within 0 7V All readings below 9 3V but within 0 7V Check electrical system and charger for problems SeeTroubleshooting Guide If problem is not found go to on charge voltage test Any readin...

Page 151: ...re 13 1 Page 13 2 Record reading Then set multimeter to 20 volts DC and place the red probe on the positive post and the black probe at the negative post of each battery Record the readings The on cha...

Page 152: ...The readings obtained as described above must be corrected for temperature For each 10 F 5 6 C above 80 F 26 7 C add 0 004 to the reading For each 10 F 5 6 C below 80 F 26 7 C subtract 0 004 from the...

Page 153: ...e post of battery no 4 Figure 13 5 Page 13 9 VEHICLE NO BATTERY NO ELECTROLYTE TEMPERATURE CORRECTION FACTOR CORRECTED SPECIFIC GRAVITY REQUIRED ACTION CELL 1 CELL 2 CELL 3 CELL 4 CELL 5 CELL 6 12 1 2...

Page 154: ...es 2 If discharge times are low less than 60 minutes replace batteries below 10 05 volts 3 In general battery sets that discharge in less than 60 minutes at 78 F 25 6 C on the discharge test will typi...

Page 155: ...appears to be okay Battery no 1 should be replaced with a bat tery that has about the same age and usage as the other batteries in the set Example 2 Vehicle no 70 was also suspected of having a bad ba...

Page 156: ...rger 3 Fully charge the batteries prior to storage 4 Store in a cool area The colder the area in which the batteries are stored the less the batteries will self discharge Batteries stored at 0 F 17 8...

Page 157: ...2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 14 1 14 SECTION 14 BATTERY CHARGER Refer to the appropriate battery charger maintenance and service manual...

Page 158: ...14...

Page 159: ...RNAL MOTOR TESTING Using a multimeter or continuity tester the following tests can be performed without disassembling the motor NOTE Tag the motor wires for identification before disconnecting TEST PR...

Page 160: ...nd or open armature windings may be the cause The motor will need to be removed from the vehicle and repaired by a qualified technician See Motor Removal on page 15a 3 TEST PROCEDURE 3 FIELD CIRCUIT O...

Page 161: ...ehicle to let the jack stands support the vehicle Figure 15a 3 Page 15a 3 See following WARNING WARNING Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydrauli...

Page 162: ...vehicle Motor Disassembly 1 Before beginning disassembly place match marks on the motor end shield and stator shell then place the motor in a vice with wooden blocks as shown Figure 15a 5 Page 15a 5...

Page 163: ...tion Disassemble the motor and carefully inspect the armature for the following characteristics Burned charred or cracked insulation Improperly cured varnish Thrown solder Flared armature windings Dam...

Page 164: ...ushes NOTE Oil on the commutator may indicate a faulty transaxle input shaft oil seal Armature Ground Test CAUTION Do not submerge the armature in solvent NOTE Before testing the armature wipe it clea...

Page 165: ...and replace brushes one at a time This method ensures the terminals and brushes will be properly positioned in the rigging Refer to Motor Assembly for brush installation See Motor Assembly on page 15a...

Page 166: ...Page 15a 8 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual 15A Figure 15a 10 Motor 16 15 18 4 6 5 3 F 1 A 1 F 2 A 2 22 29 9 TYPICAL 2 PLACES TYPICAL 2 PLACES 11 10 24 21 7 8...

Page 167: ...NOTE Make sure the bearing retainer 16 is positioned on the armature shaft before the bearing is pressed onto the armature Figure 15a 10 Page 15a 8 An arbor with an outside diameter of less than 5 8...

Page 168: ...lightly above stator shell insert the two terminal posts through insulators in stator shell wall at the A1 and A2 positions Insert brush holder screws through the holes in the brush rigging and into t...

Page 169: ...retainer 16 by aligning the two holes in the bearing retainer with the two mating holes in the end shield and installing the screws 9 Figure 15a 10 Page 15a 8 Tighten the screws to 17 in lb 1 9 N m S...

Page 170: ...1 3 cm of moly teflon lubricant CCI P N 102265201 from tube onto a putty knife as shown Figure 15a 14 Page 15a 13 2 2 Rotate wheels to rotate input shaft 2 3 Apply motor coupling grease evenly to the...

Page 171: ...the coupling 4 Install motor on transaxle 4 1 Slide the motor coupling onto the transaxle input shaft See following NOTE NOTE The coupling will push any excess grease on the input shaft along the sha...

Page 172: ...e is in operation 4 10 Connect the three pin speed sensor wire to the vehicle wire harness 5 If using a chain hoist lower the vehicle and guide the leaf springs into the shackles If using a floor jack...

Page 173: ...15a 16 3 Using a screwdriver gently pry the motor speed sensor 21 from recessed area on the motor end shield Motor Speed Sensor Installation 1 Position the motor speed sensor 21 as shown and firmly p...

Page 174: ...EL 5BC59JBS6365 Motor Speed Sensor Page 15a 16 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual 15A Motor Speed Sensor Installation Continued Figure 15a 20 IQ Motor Speed Sens...

Page 175: ...The following tests can be performed without disassembling the motor using a multimeter or continuity tester NOTE Tag the motor wires for identification before disconnecting TEST PROCEDURE 1 INTERNAL...

Page 176: ...n the S2 terminal The multimeter should indicate continuity If the reading is incorrect a possible open field coil or bad connections at the terminals may be the cause The motor will need to be remove...

Page 177: ...more room is needed remove the jack from beneath the transaxle and allow the springs to rest on the floor Figure 15b 3 Page 15b 3 9 Remove the four bolts that mount the motor to the transaxle Figure...

Page 178: ...ection on page 15b 9 3 Loosen but do not remove the two screws securing the end cap to the motor frame Figure 15b 5 Page 15b 4 4 Orient the motor so that the splined end of the armature is facing down...

Page 179: ...es disengaged from the end cap bearing NOTE Replacement of the end cap bearing is recommended if the armature is removed 9 1 Place the end cap in a press with the armature facing down 9 2 Place a bear...

Page 180: ...NSPECTION AND TESTING 1 Remove the motor from the vehicle See Motor Removal on page 15b 2 2 Remove the end cap and armature by performing steps 1 through 7 of Motor Disassembly on page 15b 4 Visual In...

Page 181: ...NOTE CAUTION Do not use emery cloth to polish the commutator Particles of emery are conductive and may short circuit the commutator bars Do not use oil or lubricants on the commutator or brushes NOTE...

Page 182: ...he C shaped plate so that it is between the spring and the brush as shown Figure 15b 13 Page 15b 9 4 3 Gently pull the scale to obtain the spring tension reading See following CAUTION CAUTION When che...

Page 183: ...ne for determining general bearing failure 1 Remove the motor from the vehicle See Motor Removal on page 15b 2 2 Remove the bearing by performing steps 1 through 14 of Motor Disassembly on page 15b 4...

Page 184: ...cedent IQ System Electric Golf Car Maintenance and Service Manual 15B Figure 15b 15 Motor 10 24 23 25 4 5 6 7 9 12 8 14 13 15 16 TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYP...

Page 185: ...e This method ensures the terminals and brushes will be properly positioned in the rigging When replacing brushes replace all four brushes Never replace only two Install the brushes in the same riggin...

Page 186: ...shes to support the weight of the commutator The brushes can be easily damaged by this weight 4 Gently press each brush with a small screwdriver until the spring rests on the end of each brush as show...

Page 187: ...1 mm from the end of the shaft and working back toward the transaxle away from the end of the shaft Figure 15b 21 Page 15b 13 2 4 The grease should be evenly distributed in the grooves to a width of a...

Page 188: ...lowing CAUTION and NOTE CAUTION Make sure the motor is properly seated in the transaxle housing NOTE Failure to install and tighten the motor mounting bolts in the proper sequence and to the proper ti...

Page 189: ...nds Lower vehicle to the floor and tighten lug nuts using a crisscross pat tern to 55 ft lb 74 6 N m 10 Place the Tow Run switch in the TOW position and connect the batteries positive cable first Tigh...

Page 190: ...15B...

Page 191: ...AXLE SHAFT Axle Shaft and Oil Seal Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Place chocks at the fron...

Page 192: ...39 Figure 16 3 Page 16 2 Retain the adapter ring and discard the oil seal 7 Inspect the axle shaft assembly to be sure the bearing and collar have not slipped and are still seated against the shoulder...

Page 193: ...nt IQ System Electric Golf Car Maintenance and Service Manual Page 16 3 16 Figure 16 5 Transaxle Type G 1 3 14 15 39 24 26 13 33 36 32 8 10 11 12 20 18 19 16 16 16 17 23 21 25 36 22 35 13 27 30 31 29...

Page 194: ...careful not to damage the seal on the inside of the axle tube hub Advance the shaft through to the bearing on the shaft then rotate it to align the shaft splines with the splined bore of the different...

Page 195: ...num frame rails forward of the spring mount Lower the vehicle to let the jack stands support the vehi cle Figure 16 6 Page 16 5 See WARNING Lift only one end of the vehicle in General Warnings Section...

Page 196: ...under motor when sliding motor off of the input shaft Fingers may get pinched when motor disengages 11 Carefully remove the motor from the transaxle Slide the motor away from the transaxle until the...

Page 197: ...arating halves 4 Remove input pinion gear 17 by pulling gear out while rocking intermediate gear assembly 19 Lift intermediate gear assembly and differential gear case unit out simultaneously Figure 1...

Page 198: ...16 3 8 2 Remove the ring gear 8 3 Separate the differential gear case housing If necessary install two of the hex bolts removed pre viously in step 8 1 into the differential gear unit and while holdin...

Page 199: ...using an arbor press Figure 16 5 Page 16 3 2 Assemble the differential gear case 2 1 Install the pin 31 Figure 16 5 Page 16 3 Apply a small amount of oil to all thrust plates and to both ends of the p...

Page 200: ...ined bore of the differential gear Continue advancing the shaft until the bearing on the axle is firmly seated within the axle tube hub seat 11 2 Using 90 internal snap ring pliers 0 090 tip CCI P N 1...

Page 201: ...wiring diagram for proper con nection See Wiring Diagrams Section 11 Page 11 2 7 Insert bolts through the spring shackles and bushings in the leaf spring eyes Secure bolts with lock nuts Tighten to 1...

Page 202: ...16...

Page 203: ...11 vibration damage 13 4 battery charger 16 hour shut off 13 5 AC service incoming 13 5 numbering vehicles and chargers 13 5 testing 13 7 on charge voltage test 13 7 battery warning light installatio...

Page 204: ...high pedal detect 11 7 I inspection front wheel free play 7 17 motor armature ground test 15a 6 15b 7 armature inspection 15a 5 15b 6 bearing 15a 7 15b 9 brush 15b 8 brush spring 15b 8 field windings...

Page 205: ...omputer OBC 11 7 installation 12 13 rebooting 11 37 removal 12 13 retrieving data from 11 39 testing 11 15 11 32 11 33 P pawl assembly 5 4 pedal group installation 5 6 removal 5 1 periodic lubrication...

Page 206: ...7 10 components control arm installation 7 14 removal 7 14 kingpin and steering spindle installation 7 13 removal 7 13 leaf spring installation 7 13 leaf spring removal 7 13 shock absorber installati...

Page 207: ...val 7 10 tire installation 8 3 removal 8 2 repair 8 2 Tow Run switch 11 7 installation 12 6 removal 12 6 testing 11 19 transaxle type g assembly 16 9 axle bearing 16 4 axle shaft installation 16 2 rem...

Page 208: ...on 3 Clarity of Illustrations 4 Index Usability 5 Troubleshooting Chart Usability Poor Fair Average Good Excellent Comments Suggestions In order to help us better serve you please rate this publicatio...

Page 209: ...Club Car R NOTES...

Page 210: ...Club Car R NOTES...

Page 211: ......

Page 212: ...Club Car Inc P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Int I 1 706 863 3000 Fax 1 706 863 5808...

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