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Club Car Carryall 1 Maintenance And Service Manual Supplement Download Page 39

ELECTRICAL SYSTEM AND TESTING

Troubleshooting

2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement

Page 11-25

11

TEST PROCEDURE 9 – 16-PIN CONNECTOR

See General Warning, Section 10, Page 10-1.

1. Disconnect the batteries and discharge the controller. 

See Disconnecting The Batteries on page 10-3.

2. Disconnect the 16-pin connector from the speed controller. Inspect terminal ends inside plug to ensure

they are in position and seated in plug housing. If any terminals look like they are not pushed all the way
into the connector, gently push the terminals until they are firmly seated in the 16-pin connector. After
each terminal has been pushed into the housing, gently pull on the wire to ensure it is locked into place.

3. Check wires in the plug to make sure none are broken at the terminal pin crimp. Repair or replace as

required.

4. Check the wire colors of each wire and make sure that the colors for each pin position match the wire

colors in the wiring diagram. 

See Wiring Diagrams beginning on page 11-2.

5. When connecting the 16-pin connector to the controller, push plug into controller receptacle with enough

force to lock plug into place. An audible click will be heard when plug is properly seated to the controller.

A procedure is provided for testing each of the wires in the 16-pin connector. Refer to the following chart for
the appropriate procedure for each pin in the 16-pin connector.

If the results of any of the referenced procedures are different from those described in the procedure, check
the continuity of the wires in the wire harness and test the connected components with the appropriate test
procedures. 

See Index of Test Procedures on page 11-16.

Test Procedure 9A – Pins 1, 2, and 3

See General Warning, Section 10, Page 10-1.

Pins 1, 2, and 3 in the 16-pin connector provide a connection point from the MCOR potentiometer to the
speed controller.

SPEED CONTROLLER 16-PIN CONNECTOR WIRE

TEST PROCEDURE

Pin 1 – White (18-gauge)

Test Procedure 9A – Pins 1, 2, and 3 on page 11-25

Pin 2 – Yellow (18-gauge)

Pin 3 – Purple/White (18-gauge)

Pin 4 – Green/White (18-gauge)

Reserved for future use. Wire serves no function at this time

Pin 5 – Light Blue (18-gauge)

Test Procedure 9B – Pin 5 on page 11-27

Pin 6 – Green (18-gauge)

Test Procedure 9C – Pin 6 on page 11-28

Pin 7 – Orange/White (18-gauge)

Test Procedure 9D – Pin 7 on page 11-29

Pin 8 – Brown (18-gauge)

Test Procedure 9E – Pins 8 and 16 on page 11-30

Pin 9 – Gray (18-gauge) with diode

Test Procedure 9F – Pin 9 on page 11-32

Pin 10 – Tan (18-gauge)

Test Procedure 9G – Pin 10 on page 11-33

Pin 11 – Open (no wire)

Pin 12 – Blue/White (18-gauge)

Test Procedure 9H – Pin 12 on page 11-34

Pin 13 – Black/White (18-gauge)

Test continuity of each wire and perform
Test Procedure 13 – Motor Speed Sensor on page 11-36

Pin 14 – Light Green (18-gauge)

Pin 15 – Red (18-gauge)

Pin 16 – Blue (18-gauge)

Test Procedure 9E – Pins 8 and 16 on page 11-30

Summary of Contents for Carryall 1

Page 1: ...Manual Number 103373106 Edition Code 1007D1210C DS Villager 4 Carryall 1 Turf 1 IQ System Electric Vehicles 2008 2011 IQ System Maintenance and Service Manual Supplement...

Page 2: ......

Page 3: ...ibutor dealer representative or by a Club Car factory trained tech nician It is the policy of Club Car LLC to assist its distributors and dealers in continually updating their service knowl edge and f...

Page 4: ...rove its vehicles 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 di...

Page 5: ...11 10 Troubleshooting the Vehicle with the IQDM 11 10 Troubleshooting Guide 1 11 11 Troubleshooting Guide 2 11 14 Test Procedures 11 16 Index of Test Procedures 11 16 Communication Display Module CDM...

Page 6: ...7 Onboard Computer OBC 13 9 Solid State Speed Controller 13 11 Charger Receptacle 13 13 Receptacle Fuse Link 13 14 Battery Warning Light 13 15 Pin 9 Diode 13 15 Ferrite Beads CE Mark Vehicles 13 17 20...

Page 7: ...17 Charging a Battery Pack that has Low Voltage 14 19 SECTION 15 BATTERY CHARGER Refer to the appropriate battery charger maintenance and service manual SECTION 16A MOTOR MODEL 5BC59JBS6390 General I...

Page 8: ...nal Insulator Inspection 16b 8 Reconditioning the Motor 16b 12 Motor Assembly 16b 12 Motor Installation 16b 14 SECTION 17 TRANSAXLE TYPE G Lubrication 17 1 Axle Bearing and Shaft 17 1 Axle Shaft 17 1...

Page 9: ...dures exactly as stated in this manual and heed all DANGER WARNING and CAUTION statements in this manual as well as those affixed to the vehicle Improper use of the vehicle or failure to properly main...

Page 10: ...cargo beds remove all cargo before raising the bed or servicing the vehicle If the vehicle is equipped with a prop rod ensure that it is securely engaged while bed is raised Do not close bed until all...

Page 11: ...ure 10 3 Page 10 3 4 After disconnecting the batteries wait 90 seconds for the controller capacitors to discharge CONNECTING THE BATTERIES 1 Ensure the Tow Run switch is in the TOW position 2 Connect...

Page 12: ...age to the vehicle and avoid the possibility of injury due to unsafe conditions Contact your local Club Car distributor dealer to perform all repairs and semiannual and annual periodic ser vice PERIOD...

Page 13: ...terminals with baking soda water solution Tires Check air pressure and adjust if necessary See Section 2 Specifications in the appropriate maintenance and service manual General vehicle Wash battery...

Page 14: ...1 Brake linkage and pivots Dry Moly Lube CC P N 1012151 Accelerator pivot rod supports Dry Moly Lube CC P N 1012151 Charger receptacle WD 40 Brake slides Dry Moly Lube CC P N 1012151 Front suspension...

Page 15: ...erator is pressed This prevents the possibility of a parked vehicle with the park brake disengaged rolling away too fast to be overtaken on foot If the walk away braking function remains engaged for t...

Page 16: ...W62 10_ORG W61 10_BLU W63 6_BLK W55 10_BLK W49 DETAIL B CONTROLLER WARNING LIGHT 1 2 KEY SWITCH MCOR SPEED SWITCH ASM THROTTLE DEVICE CONTROLLER REVERSE FORWARD PIN 1 WHITE TO HIGH SIDE OF POTENTIOME...

Page 17: ...GRAY W65 6_BLK W68 6_BLK W69 6_BLK W66 18_GRAY W52 6_BLK W55 12 VOLT BATTERIES FUSE RECEPTACLE BRACKET ASM TOW SWITCH MOTOR A1 F2 F1 A2 ON BOARD COMPUTER SONIC WELD 3 PIN CONNECTOR FUSE 101894901 INCL...

Page 18: ...11 IQ System Electric Vehicle Maintenance and Service Supplement 11 Figure 11 3 Wiring Diagram without Pin 9 Diode DS Villager 4 18_ORG W24 6_YEL W59 10_BLU W63 6_GRN W64 10_BLK W49 10_BLK W58 6_WHT W...

Page 19: ...ing Diagrams 2008 2011 IQ System Electric Vehicle Maintenance and Service Supplement Page 11 5 11 Figure 11 4 Wiring Diagram without Pin 9 Diode DS Villager 4 10_BLK W50 18_GRAY W65 18_GRAY W52 6_BLK...

Page 20: ...SYSTEM AND TESTING Wiring Diagrams Page 11 6 2008 2011 IQ System Electric Vehicle Maintenance and Service Supplement 11 Figure 11 5 Wiring Diagram with Pin 9 Diode Turf 1 and Carryall 1 Vehicles 2 3 4...

Page 21: ...SYSTEM AND TESTING Wiring Diagrams 2008 2011 IQ System Electric Vehicle Maintenance and Service Supplement Page 11 7 11 Figure 11 6 Wiring Diagram with Pin 9 Diode Turf 1 and Carryall 1 Vehicles 5 1...

Page 22: ...Q System Electric Vehicle Maintenance and Service Supplement 11 Figure 11 7 Wiring Diagram without Pin 9 Diode Turf 1 and Carryall 1 Vehicles 18_ORG W35 18_ORG W24 10_BLU W63 6_GRN W64 10_BLK W49 10_B...

Page 23: ...NG Wiring Diagrams 2008 2011 IQ System Electric Vehicle Maintenance and Service Supplement Page 11 9 11 Figure 11 8 Wiring Diagram without Pin 9 Diode Turf 1 and Carryall 1 Vehicles 10_BLK W50 18_GRAY...

Page 24: ...uter OBC The OBC 1 monitors battery condition 2 monitors the number of energy units used by the vehicle 3 determines the number of energy units required to recharge the batteries and shuts the charger...

Page 25: ...ance and service manual Test Menu SPEED PULSES menu item indicates that speed pulses are OFF when the vehicle is in motion or Diagnostic Menu SPEED SENSOR fault code Loose or disconnected motor speed...

Page 26: ...the MCOR or broken wire Repair and or connect the three pin connector to the MCOR Loose or disconnected 16 pin connector at speed controller or broken wire Repair and or connect the 16 pin connector...

Page 27: ...the selected direction with the Forward Reverse switch Diagnostic Menu LOW BATTERY fault code Batteries require charging Place batteries on battery charger and allow them to fully charge Improperly ma...

Page 28: ...rcuit on page 11 23 See also Test Procedure 4 MCOR Voltage on page 11 19 Forward Reverse rocker switch Test Procedure 15 Forward Reverse Rocker Switch on page 11 38 Solenoid loose wires Test Procedure...

Page 29: ...ual Tires under inflated or flat tires See Section 8 Wheels and Tires in the appropriate maintenance and service manual Vehicle operates but motor braking function does not Wiring improperly wired Che...

Page 30: ...ult in vehicle malfunction property damage personal injury or death INDEX OF TEST PROCEDURES 1 Batteries Voltage Check 2 Onboard Computer Solenoid Lockout Circuit 3 Solenoid Activating Coil 4 MCOR Vol...

Page 31: ...ith the batteries fully charged If not check for loose battery connec tions or a battery installed in reverse polarity Refer to Section 14 Batteries for further details on battery testing Batteries Vo...

Page 32: ...eptacle If the dash light illu minates for 10 seconds the OBC is now powered up Unplug the DC cord the reading at the OBC blue wire should be approximately 48 50 volts If the vehicle now operates norm...

Page 33: ...enoid terminal Place the black probe on the other small solenoid terminal Factory installed solenoids A reading of 200 to 250 ohms should be obtained Figure 11 12 Page 11 19 If not replace the solenoi...

Page 34: ...t the speed controller Check terminal positions in three pin connector at the MCOR and the 16 pin connector If all of the continuity readings are correct and the connectors are wired correctly replace...

Page 35: ...ly one end in General Warning Section 10 Page 10 2 2 With the batteries connected and using a multimeter set to 200 volts DC place the black probe on the A2 motor terminal white wire and connect the r...

Page 36: ...the solenoid to the two pin connector at the Tow Run switch 5 If the two pin connector and pink wire continuity readings are correct replace the Tow Run switch 6 If replacement of the Tow Run switch...

Page 37: ...enu by using the SCROLL DISPLAY buttons on the IQDM 5 2 The IQDM should indicate that FOOT INPUT is OFF when the accelerator pedal is not pressed regardless of the key switch position 5 3 With the key...

Page 38: ...ing should be approximately 48 volts full battery voltage 5 3 If the voltage reading is 48 volts when the accelerator pedal is not pressed check the pedal group for proper adjustment See Section 5 Acc...

Page 39: ...the following chart for the appropriate procedure for each pin in the 16 pin connector If the results of any of the referenced procedures are different from those described in the procedure check the...

Page 40: ...lerator pedal fully up not pressed the multimeter should read approximately 1k ohms 6 Slowly press the accelerator pedal while monitoring the multimeter The resistance should rise as the pedal is pres...

Page 41: ...11 28 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 cable fir...

Page 42: ...een wire of the 16 pin connector See following CAUTION Using an alligator clip connect the black probe to the B terminal of the speed controller Figure 11 16 Page 11 29 CAUTION Do not fully insert pro...

Page 43: ...age 11 23 Ensure that the pedal group is adjusted correctly See Section 5 Accelerator and Brake Pedal Group in the appropriate maintenance and service manual Test Procedure 9D Pin 7 See General Warnin...

Page 44: ...on page 11 21 Test Procedure 9E Pins 8 and 16 See General Warning Section 10 Page 10 1 Pins 8 and 16 in the 16 pin connector provide a connection point for the Forward Reverse rocker switch to the spe...

Page 45: ...6 pin connector Leave the black probe alligator clip connected to the B terminal of the speed controller See previous CAUTION 10 Place the Forward Reverse switch in the NEUTRAL position The multimeter...

Page 46: ...age 11 32 See following CAUTION The reading should indicate an overload no continuity A diode is designed to conduct current in one direction only If a diode conducts current shows continuity with the...

Page 47: ...ge 10 2 3 Disconnect the 16 pin connector at the speed controller 4 With a multimeter set for 200 volts DC insert the red probe of the multimeter into pin 10 tan wire of the 16 pin connector See follo...

Page 48: ...3 Disconnect the 16 pin connector at the speed controller 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 12...

Page 49: ...er gray wire and fuse See Test Procedure 11 Onboard Computer Gray Wire and Fuse on page 11 35 Red wire at the charger receptacle See Test Procedure 12 Voltage at Charger Receptacle Red Wire Socket on...

Page 50: ...in 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 connector at the speed cont...

Page 51: ...t wheels and lift the rear of the vehicle with a chain hoist or floor jack Position jack stands under the frame crossmember between the spring mount and side stringer just forward of each rear wheel S...

Page 52: ...the wiring is found to be correct pro ceed to the following procedure Forward Reverse Rocker Switch Test without the IQDM Handset for vehicles with Forward Reverse Rocker Switch mounted on the vehicle...

Page 53: ...e center dash panel Loosen but do not remove these screws 2 2 Insert screwdriver at the top center of the dash between dash and cowl brace Gently pry center dash out from under edge of cowl brace 2 3...

Page 54: ...nd connect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m and coat terminals with Battery Terminal Protector Spray CC P N 1014305 to minimize corrosion 3 Place...

Page 55: ...y units removed since last charge cycle If the display reads over 75 the vehicle battery warning light should be illuminated the vehicle batter ies need to be recharged before being used again This da...

Page 56: ...itioning CDM on seat bottom the CDM is unable to collect the data stream from the onboard computer hold CDM approximately 6 inches 15 2 cm from battery warning light 3 Wait approximately 30 seconds fo...

Page 57: ...24 Flow Chart CDM Troubleshooting Guide CDM battery is discharged Replace CDM battery Failed CDM unit Replace CDM Failed OBC Replace OBC Remove battery lead and discharge the speed controller See the...

Page 58: ...11...

Page 59: ...ULE IQDM P Programming PLUGGING THE HANDSET INTO THE VEHICLE 1 Connect one end of the cable to the jack located on the bottom of the handset 2 Connect the cable adaptor to the IQDM cable 3 Find the IQ...

Page 60: ...nu is blinking pressing the right arrow selects that menu item Pressing the left arrow allows the user to go back one screen The CHANGE VALUE BUTTON is the button located on the right side of the hand...

Page 61: ...onitor Menu on page 12 4 Faults The faults menu displays all faults recorded by the speed controller since the history was last cleared Each fault is listed only once in the history menu even if the f...

Page 62: ...has the ability to monitor the status of several components in conditions or locations where a problem with vehicle performance has been reported See following WARNING WARNING The vehicle operator sho...

Page 63: ...d Reverse switch in the NEUTRAL or REVERSE position the handset should indicate that the forward input is off When the Forward Reverse switch is placed in the FORWARD position the handset should indic...

Page 64: ...d controller for display on the fault history menu Each detected fault is listed only once in the fault history menu the number of fault occurrances are located in the fault counter section of the mon...

Page 65: ...a fast rate Fault Recovery When a fault is detected by the speed controller the speed controller will attempt to recover from the fault and resume normal operation In the case of an intermittent probl...

Page 66: ...controller outputs power greater than 75 armature PWM to the motor a speed sensor fault is detected CONTROLLER FAULT CONTROLLER FAULT CODE CONTROLLER ATTEMPTS TO RECOVER HW FAILSAFE 24 When key switch...

Page 67: ...ssing If the speed controller is operating at a duty cycle of greater than 90 almost full speed and the field current is less than 3 amps a field missing fault is detected by the speed controller HPD...

Page 68: ...ed mode See Code A Code B and Code C Section 18 Page 18 3 See also Password Tries IQDM P only on page 12 5 Fault History The fault history menu can be useful in determining the cause of a vehicle prob...

Page 69: ...orward Reverse handle in the NEUTRAL position and lock the park brake 3 Plug the handset into the vehicle 3 1 Connect one end of the cable to the jack located on the bottom of the handset 3 2 Connect...

Page 70: ...s procedure with a handset that has the desired speed controller settings See Speed Con troller Cloning Transferring Settings from the Vehicle to the Handset on page 12 11 2 Locate a vehicle that does...

Page 71: ...6 11 Repeat this procedure for additional vehicles that need to be programmed with the same handset set tings RESET ALL SETTINGS In the event that a mistake was made and one or more changes should no...

Page 72: ...scroll to information and pressing the right arrow key to activate the menu This menu selection displays information pertaining to the speed controller The information provided from this menu selecti...

Page 73: ...rtaining to the handset The information provided in this menu selection includes model number serial number the date the handset was manufactured the handset soft ware version etc IQDM AND IQDM P HAND...

Page 74: ...2 18 Contrast Setting is too light See Program on page 12 14 Onboard computer is in power down mode Drive the vehicle for a short distance and reconnect the handset to the vehicle Onboard computer mal...

Page 75: ...into one of the terminals on the end of the cord with the square plug 2 Place the black probe on each of the pins one at a time on the plug on the other end of the cord 3 The multimeter should indicat...

Page 76: ...different terminal on the end of the adaptor with the square plug TEST PROCEDURE 3 IQDM JACKS See General Warning Section 10 Page 10 1 Test Procedure 3A IQDM Jack Located Under Seat DS Villager 4 1 Li...

Page 77: ...m age and corrosion Inspect the IQDM jack mounted to the bottom of the dash panel Repair and replace parts as necessary 3 3 If no problem is found connect the multi pin connectors and install the cent...

Page 78: ...Service Supplement 12 4 7 If the handset functions when connected directly to the speed controller the adapter plug or vehicle wire harness should be thoroughly tested See Test Procedure 2 Handset Cor...

Page 79: ...Removal 1 Disconnect the batteries and discharge the controller See Disconnecting The Batteries on page 10 3 2 Remove the center dash panel Figure 13 1 Page 13 1 2 1 Remove the plastic cap 1 covering...

Page 80: ...l components mounted on the dash panel Do not allow wires to touch See following NOTE NOTE Take care to prevent key switch terminals and wires from touching the metal frame around the dash Figure 13 1...

Page 81: ...orward Reverse rocker switch mounted on the dash panel 3 1 Remove the center dash panel Figure 13 1 Page 13 1 3 1 1 Remove the plastic cap 1 covering the mounting screw 2 on each side of the center da...

Page 82: ...hten battery terminals to 110 in lb 12 4 N m and coat terminals with Battery Terminal Protector Spray CC P N 1014305 to minimize corrosion 6 Place the Tow Run switch in the RUN position 7 Inspect the...

Page 83: ...Run Switch Installation 1 Installation is reverse of removal Make sure groove on switch is aligned with tang on bracket Tighten Tow Run switch boot hex nut 6 to 16 in lb 1 8 N m Figure 13 3 Page 13 4...

Page 84: ...2 3 Disconnect the two pin and three pin connectors 1 from the MCOR 2 Figure 13 6 Page 13 6 4 Remove the hex head screws 3 connecting the MCOR to the frame I beam 5 Remove the MCOR from vehicle 6 Push...

Page 85: ...page 10 3 2 Remove center dash See step 2 of Key Switch Removal on page 13 1 3 Disconnect the 18 gauge red and orange white wires from reverse buzzer 4 Remove the two screws from the reverse buzzer Re...

Page 86: ...ten screws 12 to 60 in lb 6 8 N m 3 Using the wiring diagram install the wires resistor 9 washers 8 and nuts 7 onto the large mounting posts Tighten nuts to 77 in lb 8 7 N m See Wiring Diagrams Sectio...

Page 87: ...roller cover 1 and remove the cover Figure 13 10 Page 13 11 4 Remove the wire tie 3 securing the speed controller wires to the mounting plate 5 Remove black 6 gauge wire 14 from the speed controller B...

Page 88: ...gauge wire 8 to the charger receptacle Figure 13 9 Page 13 9 Tighten to 23 in lb 2 6 N m 6 Connect the gray wire fuse holder to the charger receptacle 7 Connect the black 6 gauge wire 14 to the speed...

Page 89: ...e Test Procedure 5 Section 11 Page 11 21 Speed Controller Removal 1 Disconnect the batteries and discharge the controller See Disconnecting The Batteries on page 10 3 2 Remove the rear body access pan...

Page 90: ...hten bolts 1 to 9 ft lb 12 2 N m Figure 13 11 Page 13 12 3 Place the edge of the speed controller cover 1 into the slot 2 Press the controller cover onto the com ponent mounting plate over the speed c...

Page 91: ...ld then be inserted and removed several times to ensure ease of inser tion ease of removal and good electrical contact Testing the Charger Receptacle See Test Procedure 12 Section 11 Page 11 35 See al...

Page 92: ...LE FUSE LINK The fuse link on the 48 volt Club Car electric vehicle should not blow under normal operating conditions how ever if the fuse link has blown the vehicle will not charge and the fuse must...

Page 93: ...1 and remove the light from the center dash Figure 13 13 Page 13 15 Battery Warning Light Installation 1 Install in reverse order of removal 2 Place the Tow Run switch in the TOW position and connect...

Page 94: ...Figure 13 14 Page 13 16 3 Splice the ends of the two wires together 4 Install a Main Dropout Harness See IQ Main Dropout Harness Installation on page 13 16 IQ Main Dropout Harness Installation 1 Disco...

Page 95: ...to compliance with EMC requirements for use in the European Union 2008 2010 MODEL YEARS Figure 13 16 Ferrite Bead Placement 2008 2010 Model Year 1 This bead goes around 2 wires green white near the mo...

Page 96: ...Figure 13 17 Ferrite Bead Placement Starting 2011 Model Year 1 This bead goes around 2 wires green white near the motor 2 This bead goes around 2 wires blue orange near the motor 3 This bead goes aro...

Page 97: ...N 1014305 to help prevent future corrosion 2 Batteries should be clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water 1 cup 237 mL baking soda per...

Page 98: ...nd is the most common type of water used in batteries Other acceptable types are deionized water and water from reverse osmosis Ordinary tap water should not be used because it contains an excessive a...

Page 99: ...causes the plates to shed prematurely and shortens the life 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 l...

Page 100: ...ery with a specific gravity lower than 1 250 will need a catch up charge If the problem continues after a catch up charge has been performed check the battery charger See Section 15 Battery Charger DE...

Page 101: ...Spread the workload evenly giving all vehicles the same amount of use This will keep your fleet in balance and will not overwork certain sets of batteries See following NOTE NOTE When vehicles are bei...

Page 102: ...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 reading...

Page 103: ...be on the positive post of battery no 1 and the black probe on the negative post of battery no 6 Figure 14 8 Page 14 18 or Figure 14 10 Page 14 18 Record reading Then set multimeter to 20 volts DC and...

Page 104: ...eye level and read the scale at the level of electrolyte Figure 14 3 Page 14 8 6 Record the reading and return the electrolyte to the cell from which it was taken Replace vent cap 7 Repeat steps 2 th...

Page 105: ...o 1 and negative post of battery no 6 last Figure 14 4 Page 14 9 or Figure 14 5 Page 14 9 VEHICLE NO BATTERY NO ELECTROLYTE TEMPERATURE CORRECTION FACTOR CORRECTED SPECIFIC GRAVITY REQUIRED ACTION CEL...

Page 106: ...e low less than 60 minutes replace batteries below 6 7 volts 3 In general battery sets that discharge in less than 60 minutes at 78 F 25 6 C on the discharge test will typically not hold a charge for...

Page 107: ...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 battery due to its pe...

Page 108: ...e the red probe on the positive post of battery no 1 and the black probe on the negative post of battery no 4 Figure 14 9 Page 14 18 Record reading Then set multimeter to 20 volts DC and place the red...

Page 109: ...t eye level and read the scale at the level of electrolyte Figure 14 3 Page 14 8 6 Record the reading and return the electrolyte to the cell from which it was taken Replace vent cap 7 Repeat steps 2 t...

Page 110: ...orrect in all cells 2 Connect the tester leads to the positive post of battery no 1 and negative post of battery no 4 Figure 14 7 Page 14 14 VEHICLE NO BATTERY NO ELECTROLYTE TEMPERATURE CORRECTION FA...

Page 111: ...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 typically not hold a...

Page 112: ...ut 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...

Page 113: ...position Tipping a battery beyond a 45 angle in any direction can allow a small amount of electrolyte to leak out the vent hole Do not exceed this 45 angle when lifting carrying or installing batterie...

Page 114: ...guration Figure 14 9 Battery Cable Removal DS Villager 4x12 Volt Battery Configuration Viewed from driver side of vehicle 1 Place TOW RUN Switch in TOW before disconnecting or connecting battery cable...

Page 115: ...ry Pack that has Low Voltage 2008 2011 IQ System Electric Vehicle Maintenance and Service Supplement Page 14 19 14 CHARGING A BATTERY PACK THAT HAS LOW VOLTAGE See the appropriate battery charger main...

Page 116: ...14...

Page 117: ...2008 2011 IQ System Electric Vehicle Maintenance and Service Supplement Page 15 1 15 SECTION 15 BATTERY CHARGER Refer to the appropriate battery charger maintenance and service manual...

Page 118: ...15...

Page 119: ...OTOR TESTING 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 PROCEDUR...

Page 120: ...2 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 removed from...

Page 121: ...low as it will go If more room is needed remove the jack from beneath the transaxle and allow the springs to rest on the floor Figure 16a 3 Page 16a 3 9 Remove the four bolts that mount the motor to t...

Page 122: ...2 5 Remove two screws 11 attaching brush rigging 12 to the stator shell 2 Figure 16a 9 Page 16a 8 6 Mark the brush terminal posts A1 and A2 13 to identify their positions in the stator shell then rem...

Page 123: ...can help determine original cause of failure Slight roughness of the commutator can be polished smooth with 400 grit or finer sandpaper See following CAUTION and NOTE CAUTION Do not use emery cloth to...

Page 124: ...Inspect the brush springs 14 Figure 16a 9 Page 16a 8 Replace springs that are discolored from heat light gold or blue tinted Replace springs which apply a force of less than 16 oz Figure 16a 7 Page 1...

Page 125: ...If a press is not available secure a bearing puller CC P N 1012811 to the bearing and pull the bearing off of the end of the armature shaft Support the shaft so it will not drop when the bearing is re...

Page 126: ...ystem Electric Vehicle Maintenance and Service Supplement 16A Figure 16a 9 Motor Model 5BC59JBS6390 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 TYPICAL 4...

Page 127: ...RECONDITIONING THE MOTOR See General Warning Section 10 Page 10 1 Motor reconditioning must be performed by a qualified motor repair technician The use of proper tools and procedures is absolutely ess...

Page 128: ...two Install the brushes in the same rigging 180 apart from each other 2 1 With brush rigging facing down and held slightly above stator shell insert the two terminal posts through insulators in stator...

Page 129: ...holes in the bearing retainer with the two mating holes in the end shield and installing the screws 9 Figure 16a 9 Page 16a 8 Tighten the screws to 17 in lb 1 9 N m See following NOTE NOTE Use a long...

Page 130: ...3 1 mm from the end of the shaft and working back toward the transaxle away from the end of the shaft Figure 16a 14 Page 16a 12 2 4 The grease should be evenly distributed in the grooves to a width of...

Page 131: ...OTE Failure to install and tighten the motor mounting bolts in the proper sequence and to the proper tightness may result in motor noise during operation 4 4 Tighten the right bolt 1 to 65 in lb 7 3 N...

Page 132: ...N m 10 Place the Tow Run switch in the TOW position and connect the batteries positive cable first Tighten battery terminals to 110 in lb 12 4 N m and coat terminals with Battery Terminal Protector Sp...

Page 133: ...re 16a 19 Page 16a 15 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 show...

Page 134: ...16A...

Page 135: ...er or distributor Beginning with utility vehicle serial number 0924 028256 the CC P N 102705001 IQ Electric Motor Model EJ4 4001 was replaced with CC P N 103572501 IQ Electric Motor Model EJ8 4001A Co...

Page 136: ...ecting The Batteries on page 10 3 2 Disconnect wires from the A1 and A2 terminals on the motor using two wrenches to prevent posts from turning Set a multimeter to 200 ohms and place the red probe on...

Page 137: ...he vehicle to let the jack stands support the vehicle Figure 16b 2 Page 16b 3 See following WARNING WARNING Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydr...

Page 138: ...on the floor Figure 16b 3 Page 16b 4 9 Remove the bolts that mount the motor to the transaxle Figure 16b 24 Page 16b 16 See following CAUTION CAUTION Do not position fingers under motor when sliding m...

Page 139: ...e loose where it connects to the motor frame proceed to step 6 otherwise disengage the end cap from the motor frame using the following procedure 5 1 With the end cap bolts loose about 1 4 inch betwee...

Page 140: ...ave an assistant support the armature while the press is activated 10 Inspect the armature for wear and damage See Armature Inspection and Testing on page 16b 7 11 Inspect the motor frame and field wi...

Page 141: ...indings Damaged armature core laminations Worn burned or glazed commutators Dirty or oily commutators Raised commutator bars Worn armature bearing or shaft A dirty or oily commutator should be cleaned...

Page 142: ...the armature MOTOR FRAME AND FIELD WINDINGS INSPECTION 1 Remove the motor from the vehicle See Motor Removal Section 16b Page 16b 3 2 Remove the and cap and armature by performing steps 1 through 7 of...

Page 143: ...ess than 35 oz 990 grams Figure 16b 13 Page 16b 10 See following NOTE NOTE When installing new brushes remove and replace brushes one at a time This method ensures the terminals and brushes will be pr...

Page 144: ...guideline for determining general bearing failure 1 Remove the motor from the vehicle See Motor Removal Section 16b Page 16b 3 2 Remove the bearing by performing steps 1 through 14 of Motor Disassembl...

Page 145: ...c Vehicle Maintenance and Service Supplement Page 16b 11 16B Figure 16b 15 Motor Models EJ4 4001 and EJ8 4001A 10 24 23 25 4 5 6 7 9 12 8 14 13 15 16 TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES...

Page 146: ...at a time 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 sam...

Page 147: ...o 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 shown Figu...

Page 148: ...nch 3 1 mm from the end of the shaft and working back toward the transaxle away from the end of the shaft Figure 16b 21 Page 16b 14 2 4 The grease should be evenly distributed in the grooves to a widt...

Page 149: ...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 tightness may result in motor noi...

Page 150: ...en 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 Tighten battery terminals to 110 in lb 12 4...

Page 151: ...T Axle Shaft and Oil Seal Removal 1 Disconnect the batteries and discharge the controller See Disconnecting The Batteries on page 10 3 2 Place chocks at the front wheels Loosen lug nuts on rear wheels...

Page 152: ...r ring 39 Figure 17 3 Page 17 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 s...

Page 153: ...Q System Electric Vehicle Maintenance and Service Supplement Page 17 3 17 Figure 17 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 2...

Page 154: ...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 differential side ge...

Page 155: ...forward of each rear wheel Lower the vehicle to let the jack stands support the vehicle Figure 17 6 Page 17 5 See WARNING Lift only one end of the vehicle in General Warning Section 10 Page 10 1 3 Re...

Page 156: ...when sliding motor off of the input shaft Fingers may get pinched when motor disengages 10 Carefully remove the motor from the transaxle Slide the motor away from the transaxle until the motor spline...

Page 157: ...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 17 5 Page 17 3 Se...

Page 158: ...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 holding the...

Page 159: ...earings using an arbor press Figure 17 5 Page 17 3 2 Assemble the differential gear case 2 1 Install the pin 31 Figure 17 5 Page 17 3 Apply a small amount of oil to all thrust plates and to both ends...

Page 160: ...lines with the splined 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...

Page 161: ...r 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 locknuts Tighten to 15 ft lb 20 3 N m 8 Connect...

Page 162: ...17...

Page 163: ...ct one end of the cable to the jack located on the bottom of the handset 2 Connect the cable adaptor to the IQDM cable 3 Find the IQDM jack on the vehicle 4 Remove the dust cap from the IQDM jack 5 Al...

Page 164: ...the handset from the program menu SPEED SETTING The vehicle s top speed can be changed by selecting values 1 through 3 Figure 18 4 If a value of 4 is dis played for the speed setting a special access...

Page 165: ...ding on the slope of the incline See Speed Setting on page 18 2 SPEED CAL The speed cal speed calibration menu item allows the user to fine tune the vehicle speed This feature can not be used to incre...

Page 166: ...IQ DISPLAY MODULE IQDM P PROGRAMMING Plugging the Handset into the Vehicle Page 18 4 2008 2011 IQ System Electric Vehicle Maintenance and Service Supplement 18...

Page 167: ...sting 14 7 14 12 on charge voltage test 14 7 14 12 battery warning light installation 13 15 removal 13 15 13 16 testing 11 40 bearing axle see transaxle type g axle bearing bearing motor see motor bea...

Page 168: ...ing 11 1 protection circuit 11 10 reconditioning 16a 9 16b 12 removal 16a 2 16b 3 service specifications 16a 9 16b 12 speed sensor 16a 15 installation 16a 15 removal 16a 15 testing 11 36 speed sensor...

Page 169: ...everse buzzer 11 39 17 OBC rebooting 11 40 18 battery warning light 11 40 test procedures IQDM 1 handset cord 12 17 2 handset cord adaptor 12 18 3 IQDM jacks 12 18 test procedures motor 1 internal sho...

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Page 171: ...ng Information 3 Clarity of Illustrations Photos 4 Index Usability In order to help us better serve you please rate this publication in the following categories Poor Fair Average Good Excellent 5 If y...

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Page 176: ...Club Car LLC P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Int l 1 706 863 3000 Fax 1 706 863 5808...

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