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Club Car IQ PLUS 2008 Maintenance And Service Manual Supplement Download Page 6

Page iv

2008-2011 IQ Plus Electric Vehicle Maintenance and Service Supplement

Programmer Setup ........................................................................................................................... 12-18

Program ....................................................................................................................................... 12-18
Faults ........................................................................................................................................... 12-18
Information ................................................................................................................................... 12-18

IQDM and IQDM-P Handset Troubleshooting .................................................................................. 12-19
Test Procedures ............................................................................................................................... 12-20

Index of Test Procedures  ............................................................................................................. 12-20

SECTION 13 – ELECTRICAL COMPONENTS

Key Switch  .......................................................................................................................................

13-1

Forward/Reverse Rocker Switch ......................................................................................................

13-3

Tow/Run Switch  ...............................................................................................................................

13-4

Circuit Breaker  .................................................................................................................................

13-5

Motor Controller Output Regulator (MCOR) .....................................................................................

13-6

Reverse Buzzer ................................................................................................................................

13-7

Speed controller cover  .....................................................................................................................

13-7

Solenoid ...........................................................................................................................................

13-8

Onboard Computer (OBC)  ............................................................................................................... 13-10
Solid State Speed Controller ............................................................................................................ 13-11
Charger Receptacle  ......................................................................................................................... 13-13

Receptacle Fuse Link ................................................................................................................... 13-14

Battery Warning Light ....................................................................................................................... 13-15
Ferrite Beads – CE Mark vehicles .................................................................................................... 13-15

SECTION 14 – BATTERIES

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

14-1

Battery Replacement ........................................................................................................................

14-2

Battery Care  .....................................................................................................................................

14-4

Preventive Maintenance ...............................................................................................................

14-4

Self-Discharge ..............................................................................................................................

14-4

Electrolyte Level ...........................................................................................................................

14-4

Water Quality ................................................................................................................................

14-5

Vibration Damage .........................................................................................................................

14-6

Battery Charging  ..............................................................................................................................

14-7

Charger Shuts Off After 16 Hours  ................................................................................................

14-7

Deep-Discharge ...........................................................................................................................

14-7

Early Excessive Discharging  ........................................................................................................

14-7

Incoming AC Service ....................................................................................................................

14-8

Fleet Rotation  ...............................................................................................................................

14-8

Numbering Vehicles and Chargers  ..............................................................................................

14-8

Summary of Contents for IQ PLUS 2008

Page 1: ...Manual Number 103373107 Edition Code 1107B1210A IQ Plus Electric Vehicles 2008 2011 IQ Plus Maintenance and Service Manual Supplement...

Page 2: ......

Page 3: ...ealer 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 facilitie...

Page 4: ...ove 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 dis...

Page 5: ...e with the IQDM 11 8 Troubleshooting Guide 1 11 9 Troubleshooting Guide 2 11 12 Test Procedures 11 14 Index of Test Procedures 11 14 Communication Display Module CDM 11 45 Using the CDM to Retrieve Da...

Page 6: ...zer 13 7 Speed controller cover 13 7 Solenoid 13 8 Onboard Computer OBC 13 10 Solid State Speed Controller 13 11 Charger Receptacle 13 13 Receptacle Fuse Link 13 14 Battery Warning Light 13 15 Ferrite...

Page 7: ...A5 4006 General Information 16 1 External Motor Testing 16 1 Motor 16 2 Motor Removal 16 2 Motor Disassembly 16 4 Motor Component Testing and Inspection 16 6 Armature Inspection and Testing 16 6 Motor...

Page 8: ...rvice Supplement SECTION 18 IQ DISPLAY MODULE IQDM P SERIES 2 PROGRAMMING Plugging the Handset into the Vehicle 18 1 Program Menu 18 2 M1 M2 Speed 18 2 M1 M2 Fast Accel 18 3 M1 M2 Pedal Up 18 3 M1 M2...

Page 9: ...d 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 maintain it could result in decreased vehicle perf...

Page 10: ...the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes For vehicles with cargo beds remove all...

Page 11: ...ion or severe personal injury 3 Disconnect the batteries negative cable first as shown Figure 10 1 Page 10 2 Figure 10 2 Page 10 2 or Figure 10 3 Page 10 3 4 After disconnecting the batteries wait 90...

Page 12: ...ibutor dealer to perform all repairs and semiannual and annual periodic ser vice PERIODIC SERVICE SCHEDULE WARNING Service repairs and adjustments must be made per instructions in the appropriate main...

Page 13: ...ction 2 Specifications in the appropriate maintenance and service manual General vehicle Wash battery compartment and underside of vehicle Semiannual service by trained technician only or every 50 hou...

Page 14: ...vots Dry Moly Lube CC P N 1012151 Accelerator pivot rod supports Dry Moly Lube CC P N 1012151 Charger receptacle if equipped WD 40 Brake slides Dry Moly Lube CC P N 1012151 Front suspension up to 5 fi...

Page 15: ...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 two seconds or more a warning bu...

Page 16: ...CAL SYSTEM AND TESTING Wiring Diagrams Page 11 2 2008 2011 IQ Plus Electric Vehicle Maintenance and Service Supplement 11 WIRING DIAGRAMS Figure 11 1 Wiring Diagram Carryall 2 and Turf 2 Vehicles 0005...

Page 17: ...ELECTRICAL SYSTEM AND TESTING Wiring Diagrams 2008 2011 IQ Plus Electric Vehicle Maintenance and Service Supplement Page 11 3 11 Figure 11 2 Wiring Diagram Carryall 2 and Turf 2 Vehicles 000566 001...

Page 18: ...ing Diagrams Page 11 4 2008 2011 IQ Plus Electric Vehicle Maintenance and Service Supplement 11 Figure 11 3 Wiring Diagram Carryall 6 Transporter 4 and 6 Vehicles PIN 9 PINK TO RELAY COIL B PIN 8 GREE...

Page 19: ...CTRICAL SYSTEM AND TESTING Wiring Diagrams 2008 2011 IQ Plus Electric Vehicle Maintenance and Service Supplement Page 11 5 11 Figure 11 4 Wiring Diagram Carryall 6 Transporter 4 and 6 Vehicles 000580...

Page 20: ...ING Wiring Diagrams Page 11 6 2008 2011 IQ Plus Electric Vehicle Maintenance and Service Supplement 11 Figure 11 5 Wiring Diagram Villager 6 and 8 Vehicles PIN 9 PINK TO RELAY COIL B PIN 8 GREEN TO MC...

Page 21: ...ELECTRICAL SYSTEM AND TESTING Wiring Diagrams 2008 2011 IQ Plus Electric Vehicle Maintenance and Service Supplement Page 11 7 11 Figure 11 6 Wiring Diagram Villager 6 and 8 Vehicles 000581 001...

Page 22: ...gnostic History menu See 06 HPD Section 12 Page 12 11 Onboard Computer OBC The OBC 1 monitors battery condition 2 monitors the number of energy units used by the vehicle 3 determines the number of ene...

Page 23: ...u 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 sensor or broken wire Repair and...

Page 24: ...onnector at the MCOR or broken wire Repair and or connect the three pin connector to the MCOR Loose or disconnected 24 pin connector at speed controller or broken wire Repair and or connect the 24 pin...

Page 25: ...he 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 mai...

Page 26: ...and MCOR Limit Switch Circuit on page 11 23 See also Test Procedure 4 MCOR Voltage on page 11 18 Forward Reverse rocker switch Test Procedure 16 Forward Reverse Rocker Switch on page 11 41 Solenoid lo...

Page 27: ...ate maintenance and service manual Vehicle operates but motor braking function does not Wiring improperly wired Check vehicle wiring See Wiring Diagrams beginning on page 11 2 Speed sensor disconnecte...

Page 28: ...ction 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 Voltage 5 A1 and A2 Moto...

Page 29: ...Test menu and select BATT VOLTAGE by using the SCROLL DISPLAY buttons The IQDM should indicate at least 48 volts with the batteries fully charged If not check for loose battery connec tions or a batte...

Page 30: ...lts check the wire ter minal connectors inside the 24 pin connector or for possible broken wires Make sure pins are properly aligned inside housing Make sure wire colors match and are connected to the...

Page 31: ...er on the positive solenoid terminal Place the black probe on the other small solenoid terminal A reading of 180 to 190 ohms should be obtained Figure 11 10 If not replace the solenoid 4 If a failed d...

Page 32: ...dicate 0 with the pedal not pressed While monitoring the IQDM display screen slowly press the accelerator pedal As the pedal is pressed the IQDM should indicate a rise from 0 pedal not pressed to 100...

Page 33: ...troller Check terminal positions in three pin connector at the MCOR and the 24 pin connector If all of the continuity readings are correct and the connectors are wired cor rectly replace the speed con...

Page 34: ...timeter The resistance should rise as the pedal is pressed When the pedal is all the way to the floor the multimeter should indicate between 5 67k ohms and 7 43k ohms 8 6 Using a multimeter set for 20...

Page 35: ...ding or if there is no increase in voltage as the pedal is pressed check the MCOR See Test Procedure 4 MCOR Voltage on page 11 18 Also check the continuity of the large posts of the solenoid See Test...

Page 36: ...e close to the two pin connector on the Tow Run switch Figure 11 15 2 If the reading is 48 50 volts proceed to Step 3 If the voltage reading is 0 volts check the continuity of the pink 18 gauge wire f...

Page 37: ...lts the batteries are deeply discharged or have failed 6 Recording the battery pack voltage reading while under load provides a more accurate diagnosis of the condition of the batteries When the disch...

Page 38: ...in General Warning Section 10 Page 10 1 3 Turn the key switch to the OFF position and place the Forward Reverse switch in the NEUTRAL position 4 Test the key switch 4 1 Remove the center dash panel Se...

Page 39: ...ST PROCEDURE 10 24 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 24 pin c...

Page 40: ...TEST PROCEDURE Pin 1 Tan 18 gauge Test Procedure 10F Pin 1 on page 11 33 Pin 2 Light Blue 18 gauge Test Procedure 2 Onboard Computer Solenoid Lockout Circuit on page 11 16 Pin 3 Orange 18 gauge Test...

Page 41: ...5 67k ohms and 7 43k ohms 7 Set a multimeter to 20k ohms Insert the red probe of the multimeter into pin 15 yellow wire at the 24 pin connector Connect the black probe into pin 13 white wire See previ...

Page 42: ...11 29 CAUTION Do not fully insert probes into the 24 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 firs...

Page 43: ...LECTRICAL SYSTEM AND TESTING Troubleshooting 2008 2011 IQ Plus Electric Vehicle Maintenance and Service Supplement Page 11 29 11 Figure 11 19 Test Pin 2 Light Blue Wire Detail Front of 24 Pin Connecto...

Page 44: ...f the 24 pin connector See following CAUTION Using an alligator clip connect the black probe to the B terminal of the speed controller Figure 11 20 Page 11 30 CAUTION Do not fully insert probes into t...

Page 45: ...eries on page 10 3 2 Place chocks at the front 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 si...

Page 46: ...de stringer just forward of each rear wheel See WARNING Lift only one end in General Warning Section 10 Page 10 1 3 Disconnect the 24 pin connector at the speed controller 4 Set a multimeter to 200 vo...

Page 47: ...uld still indicate zero volts 12 Place the Forward Reverse switch in the REVERSE position The multimeter should indicate full battery voltage approximately 48 volts 13 If any other reading is obtained...

Page 48: ...fully insert probes into the 24 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 first Tighten battery ter...

Page 49: ...bserved check the following items Continuity of the wires in the wire harness Reverse buzzer for proper operation See Test Procedure 17 Reverse Buzzer on page 11 42 Tow Run switch for proper operation...

Page 50: ...ing current Use the following procedure to test the SCR 1 With batteries connected and a multimeter set to 200 volts DC place the red probe on the positive post of battery no 1 and place the black pro...

Page 51: ...y is activated the reading should rise to approximately 48 volts 4 If voltage does not drop to less than 5 volts when the DC cord is plugged in and then rise to approximately 48 volts when the charger...

Page 52: ...te ON for speed sensor pulses while the wheels are in motion 5 If the IQDM does not indicate ON while the wheels are in motion proceed to the following procedure Motor Speed Sensor Test without the IQ...

Page 53: ...ontroller 4 3 If the reading is below 14 volts replace the speed controller 4 4 If the voltage reading is correct proceed to the following step 5 Check voltage at the light green wire 5 1 Set a multim...

Page 54: ...nd Slowly turn the rear wheel to rotate the motor armature As the armature rotates the voltage reading should alternate from zero to approximately 4 85 volts The voltage reading will fluctuate from ze...

Page 55: ...ect FORWARD INPUT by using the SCROLL DISPLAY buttons The IQDM should indicate OFF when the Forward Reverse switch is in the NEUTRAL or REVERSE position 3 2 Place the Forward Reverse switch in the FOR...

Page 56: ...ng screw on each side of the center dash panel 2 2 Loosen but do not remove the screw on each side of the center dash panel 2 3 Insert screwdriver at the top center of the dash between dash and cowl b...

Page 57: ...tive 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 Tow Run switch in the RUN positio...

Page 58: ...12 1 3 Check the FAULTS Menu 4 If a 15 RELAY DNC or 30 RELAY COIL FAULT is shown in the list a walk away braking fault has occurred Walk Away Braking Relay Test without the IQDM Handset 1 Turn the ke...

Page 59: ...in the charge circuit F2 Energy 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 b...

Page 60: ...ht and there is a clear path between them See following NOTE NOTE If by positioning CDM on seat bottom the CDM is unable to collect the data stream from the onboard computer hold CDM approximately 6 i...

Page 61: ...n Figure 11 33 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 control...

Page 62: ...11...

Page 63: ...the IQDM P handset programming features see Section 18 IQ DIS PLAY MODULE IQDM P Programming PLUGGING THE HANDSET INTO THE VEHICLE 1 Connect one end of the cable to the jack located on the bottom of...

Page 64: ...the right side of the handset Figure 12 2 Page 3 This button allows the user to change values by pressing or The three yellow buttons labeled 1 2 and 3 are BOOKMARK BUTTONS Figure 12 2 Page 3 These b...

Page 65: ...tions menu allows the user to transfer all current settings from the speed controller to the handset and from the handset to the speed controller See Functions Menu on page 12 14 Information The infor...

Page 66: ...ates the approximate ground speed of the vehicle in miles per hour MPH Throttle Indicates the position of the accelerator pedal from 0 pedal not pressed to 95 100 pedal fully pressed This item can be...

Page 67: ...t 0 and the vehicle is moving the relay will activate reversing the direction of the field current until no motion of the vehicle is detected Main Cont Displays the state of the solenoid main contacto...

Page 68: ...s the number of times the MAIN DRV ON fault has been detected See Fault Descriptions on page 12 11 Main Coil OPN Displays the number of times the MAIN COIL OPN fault has been detected See Fault Descri...

Page 69: ...VR Overcur Displays the number of times the DRVR OVERCUR fault has been detected See Fault Descriptions on page 12 11 RLY DRVR On Displays the number of times the RLY DRVR ON fault has been detected S...

Page 70: ...etected it is stored in the memory of the speed 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 l...

Page 71: ...il speed sensor pulses occur 7 Gradually reduce Regen Current Limit 8 SmartKey functions NOT enabled 9 PASSWORD TRIES count incremented 10 Set Internal Scaled Throttle Signal to Zero 11 Turn off Walk...

Page 72: ...OPOUT Throttle applied 3 12 Throttle applied 13 MOTOR STALL Throttle applied 6 Speed pulses appear 14 MAIN DRIVER OFF Throttle applied 3 10 Condition clears 15 RELAY DNC WalkAway 2 13 Throttle applied...

Page 73: ...07 Main Welded If the speed controller detects that the solenoid contacts are welded closed a main welded fault is detected 08 Relay Welded If the speed controller detects that the external Walk Away...

Page 74: ...B controller terminals a pre charge fault is detected 22 Field Missing 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 a...

Page 75: ...t password fault is declared See Code A Code B and Code C Section 18 Page 18 5 See also Password Tries IQDM P only on page 12 5 Fault History The fault history menu can be useful in determining the ca...

Page 76: ...Forward 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 Connec...

Page 77: ...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 14 2 Locate a vehicle that does...

Page 78: ...the next few seconds while the controller settings are being stored in the handset s memory Figure 12 3 10 When the handset is finished transferring the speed controller settings a confirmation messag...

Page 79: ...l to the functions menu and select 2 Select settings 3 Select reset all settings 4 Press on the change value button to confirm the operation 5 The handset will display an executing message for the nex...

Page 80: ...s faults menu does not pertain to any faults detected in the speed controller The following faults can be detected within the handset Fault History This menu displays any faults that have been detecte...

Page 81: ...Procedure 2 Handset Cord Adaptor on page 12 20 IQDM jack on vehicle has failed Test Procedure 3 IQDM Jacks on page 12 21 Contrast Setting is too light See Program on page 12 18 Onboard computer is in...

Page 82: ...10 1 1 Using a multimeter set for 200 ohms place the red probe 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 pl...

Page 83: ...UTRAL position and lock the park brake 2 Place the Tow Run switch in the TOW position disconnect the batteries negative cable first and wait 90 seconds for the speed controller capacitors to discharge...

Page 84: ...1 from the speed controller 1 3 Connect the handset cord to the handset 1 4 Connect the other end of the handset cord without the adapter to the four pin connector of the speed controller 1 5 Connect...

Page 85: ...nel Figure 13 1 Page 13 1 2 1 Remove the plastic cap 1 covering the mounting screw 2 on each side of the center dash panel 3 Figure 13 1 Page 13 1 2 2 Loosen but do not remove the screw 2 on each side...

Page 86: ...d tighten the switch retaining nut 6 to 40 in lb 4 5 N m Install key switch cap 8 in center dash Figure 13 2 Page 13 2 2 Refer to the wiring diagram to connect the wires to the key switch terminals an...

Page 87: ...ires to the rocker switch exactly as shown in the wiring diagram See Wiring Diagrams Section 11 Page 11 2 3 Install center dash by reversing removal procedure Make sure key switch terminals do not tou...

Page 88: ...3 Remove Tow Run switch 10 and nut 9 from bracket 5 4 Disconnect the two pin connector 7 and remove switch Tow Run Switch Installation 1 Installation is reverse of removal Make sure groove on switch...

Page 89: ...connectors 4 on the back of the circuit breaker Circuit Breaker Installation 1 Installation is reverse of removal Connect tan and green wires to the spade connectors 4 on the back of the circuit brea...

Page 90: ...2 Place chocks at rear wheels and lift the front of the vehicle with a chain hoist or floor jack Place jack stands under the round tube crossmember of the frame to support vehicle See WARNING Lift on...

Page 91: ...sion REVERSE BUZZER See General Warning Section 10 Page 10 1 Testing the Reverse Buzzer See Test Procedure 17 Section 11 Page 11 42 Reverse Buzzer Removal 1 Disconnect the batteries and discharge the...

Page 92: ...OLENOID See General Warning Section 10 Page 10 1 The solenoid is located on the passenger side of the electrical component mounting plate Testing the Solenoid See Section 11 Test Procedure 3 Page 11 1...

Page 93: ...o the large mounting posts Tighten nuts to 77 in lb 8 7 N m See Wiring Diagrams Section 11 Page 11 2 4 Install the blue white and light blue wires onto the small terminals of the solenoid Figure 13 7...

Page 94: ...nnect the 6 pin connector from the OBC to the main wiring harness 8 Disconnect the gray wire from the OBC 9 Loosen but do not remove the three self tapping screws 2 holding OBC to component mounting p...

Page 95: ...e the Tow Run switch in the TOW position and 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...

Page 96: ...ition and 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...

Page 97: ...Disconnecting The Batteries on page 10 3 2 Remove the 10 gauge red wire from the connector plug 10 Figure 13 11 Page 13 14 3 Remove black 10 gauge OBC wire from charger receptacle 4 Disconnect the gr...

Page 98: ...Disconnecting The Batteries on page 10 3 2 Remove the fuse link 6 from the charger receptacle 5 by removing the two nuts and washers used to secure the 10 gauge black wire 11 from the computer and the...

Page 99: ...nnect the brown wire at the quick disconnect terminal and remove the orange white wire from the key switch 4 Press the two retaining tabs 11 and remove the light from the center dash Figure 13 12 Page...

Page 100: ...r wires To install either type of ferrite bead release the two tabs on the side of the ferrite bead to open and place onto wire or wires Close the ferrite bead and press the tabs until they snap close...

Page 101: ...ite bead cut the wire tie and release the two tabs on the side of the ferrite bead to open and remove from wire or wires To install either type of ferrite bead release the two tabs on the side of the...

Page 102: ...13...

Page 103: ...Eyes Flush with water for 15 minutes Call a physician immediately WARNING Wear safety glasses or approved eye protection when servicing the vehicle or battery charger Wear a full face shield and rubbe...

Page 104: ...new batteries for any damage that may have occurred in transit 3 If the battery cables are to be reused inspect them for broken or frayed wires damaged terminals or worn insulation Remove any corrosi...

Page 105: ...ack or buckle bat tery case 6 Install wires in proper sequence Figure 14 1 14 2 or 14 3 on Page 14 3 Install black wire to negative post of battery no 8 last Make sure all connections are tight Tighte...

Page 106: ...water 1 cup 237 mL baking soda per 1 gallon 3 8 L of water Rinse solution off bat teries Do not allow this solution to enter the batteries Be sure terminals are tight Let the terminals dry and then c...

Page 107: ...Distilled water is produced by distillation a process in which water is boiled the steam is collected and then condensed back into water This process creates a finished product free of minerals havin...

Page 108: ...rounding metal parts The acid which is lost reduces the capacity of the battery and cannot be replaced Battery hold downs should NOT be so tight as to crack or buckle the battery case This may cause l...

Page 109: ...the vehicles do not get used check the batteries for state of charge Any battery with a specific gravity lower than 1 250 will need a catch up charge If the problem continues after a catch up charge h...

Page 110: ...ead 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 being...

Page 111: ...ove 5 25 V and within 0 5 V All readings below 5 25 V but within 0 5 V Check electrical system and charger for problems SeeTroubleshooting Guide If problem is not found go to on charge voltage test An...

Page 112: ...Place the red probe on the positive post of battery no 1 and the black probe on the negative post of battery no 8 Record reading Then set multimeter to 20 volts DC and place the red probe on the posi...

Page 113: ...read the scale at the level of electrolyte Figure 14 6 Page 14 11 6 Record the reading and return the electrolyte to the cell from which it was taken Replace vent cap 7 Repeat steps 2 through 6 on al...

Page 114: ...attery 4 Reset discharge machine and turn the tester ON 5 When the batteries have been discharging for approximately 60 minutes set the discharge machine to function 3 and check battery set voltage Ch...

Page 115: ...that delivers 62 minutes at 80 F 26 7 C BATTERY VOLTAGES BATTERY CONDITION 1 2 3 4 5 6 7 8 5 25 V 5 25 V 5 25 V 5 25 V 5 25 V 5 25 V 5 25 V 5 25 V Excellent 5 30 V 5 30 V 5 45 V 4 70 V 5 30 V 5 30 V...

Page 116: ...placed 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 performance The battery cha...

Page 117: ...rage 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 C will discharge very little over a four month...

Page 118: ...14...

Page 119: ...2008 2011 IQ Plus 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 120: ...15...

Page 121: ...S 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 wires from terminals on motor using two wre...

Page 122: ...eld coil or bad connections at the terminals 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 16 2 MOTOR See General...

Page 123: ...ow 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 16 3 Page 16 3 9 Remove the four bolts that mount the motor to the...

Page 124: ...2 Remove the bolt 13 securing the magnet 12 to the armature shaft 15 Hold the back of the armature assembly to keep it from turning as you remove the bolt 3 3 Inspect the speed sensor magnet See Speed...

Page 125: ...Page 16 4 8 2 Place the end cap in a press with the armature facing down 8 3 Place a bearing press tool with an outer diameter smaller than that of the armature shaft between the press ram and the ar...

Page 126: ...ed 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 and wiped dr...

Page 127: ...r from the vehicle See Motor Removal Section 16 Page 16 2 2 Remove the end cap and armature by performing steps 1 through 6 of Motor Disassembly on page 16 4 3 Burned or scorched insulation on the fie...

Page 128: ...ew brushes remove 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 As...

Page 129: ...g general bearing failure 1 Remove the motor from the vehicle See Motor Removal Section 16 Page 16 2 2 Remove the bearing by performing steps 1 through 13 of Motor Disassembly on page 16 4 3 Use a cle...

Page 130: ...or Component Testing and Inspection Page 16 10 2008 2011 IQ Plus Electric Vehicle Maintenance and Service Supplement 16 Figure 16 13 Motor MOTOR MOUNTING 22 2 TYPICAL 3 PLACES 4 1 23 13 10 11 9 12 18...

Page 131: ...brushes remove and replace brushes one at a time This method ensures the terminals and brushes will be properly positioned in the rigging When replacing brushes replace all eight brushes Install the b...

Page 132: ...Tighten to 65 in lb 7 3 N m 7 Install the speed sensor 10 with two screws 11 Tighten to 25 in lb 2 8 N m 8 Make sure the armature turns freely If it does not turn freely disassemble the motor to find...

Page 133: ...tely clean of grease as shown Figure 16 18 Page 16 14 3 Install motor on transaxle 3 1 Slide the motor coupling onto the transaxle input shaft See following NOTE NOTE The coupling will push any excess...

Page 134: ...ct See Wiring Diagrams Section 11 Page 11 2 Tighten the terminal retaining nuts to 65 in lb 7 3 N m Use a wrench on the bottom nuts to keep the terminals from moving 3 9 Secure the white orange green...

Page 135: ...ch in the RUN position 11 Inspect the vehicle for proper operation See following WARNING WARNING Make sure that the vehicle operates in the forward direction when the Forward Reverse switch is in the...

Page 136: ...16...

Page 137: ...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 138: ...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 shoulder o...

Page 139: ...lus Electric Vehicle Maintenance and Service Supplement Page 17 3 17 Figure 17 5 Transaxle Type G 1 3 14 15 REFERENCE MOTOR 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...

Page 140: ...o 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 gear...

Page 141: ...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 Rem...

Page 142: ...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 143: ...rating 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 17...

Page 144: ...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 u...

Page 145: ...ing 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 of the pin...

Page 146: ...ines 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 147: ...ing 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 locknuts Tighten to 15 ft...

Page 148: ...17...

Page 149: ...enu navigation and monitor faults and fun tion menus See Section 12 IQ DISPLAY MODULE IQDM and IQDM P Diagnostics PLUGGING THE HANDSET INTO THE VEHICLE 1 Connect one end of the cable to the jack locat...

Page 150: ...gram menu NOTE M1 refers to Mode 1 and M2 refers to Mode 2 To activate Mode 2 in the IQDM P Series 2 Code A Code B and Code C must be entered See Code A Code B and Code C on page 18 5 All set tings in...

Page 151: ...released motor braking will slow the vehicle to a stop when pedal up motor braking is enabled option 1 or 2 If pedal up motor braking is disabled option 0 the vehicle will coast to a stop when the ped...

Page 152: ...h 14 2 mph 22 9 km h 16 2 mph 26 1 km h 9 7 1 mph 11 4 km h 11 1 mph 17 9 km h 14 1 mph 22 7 km h 16 1 mph 26 0 km h 10 7 0 mph 11 3 km h 11 0 mph 17 7 km h 14 0 mph 22 5 km h 16 0 mph 25 7 km h 11 6...

Page 153: ...ode entries are used to activate Mode 2 M2 functions in the Program Menu Each vehicle has a unique code for placing the vehicle in this mode Once activated Mode 2 settings can be programmed using the...

Page 154: ...18...

Page 155: ...est 14 10 battery warning light installation 13 15 removal 13 15 testing 11 43 bearing axle see transaxle type g axle bearing bearing motor see motor bearing braking motor see regenerative braking bra...

Page 156: ...stallation 16 12 motor braking 11 1 protection circuit 11 8 reconditioning 16 11 removal 16 2 service specifications 16 11 speed sensor testing 11 38 speed sensor magnet inspection 16 9 testing 11 21...

Page 157: ...er 11 42 18 OBC rebooting 11 43 19 battery warning light 11 43 20 zero speed detect relay 11 44 test procedures motor 1 internal short circuits 16 1 2 armature circuit open 16 1 3 field circuit open 1...

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Page 159: ...g 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 yo...

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Page 161: ...Club Car R NOTES...

Page 162: ...Club Car R NOTES...

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Page 164: ...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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