Club Car IQ PLUS SYSTEM Maintenance Service Supplement Download

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MOTOR (MODEL DA5-4006)

Motor Component Testing and Inspection

Page 16-6

2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement

MOTOR COMPONENT TESTING AND INSPECTION

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

ARMATURE INSPECTION AND TESTING

1. Remove the motor 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.

Visual Inspection

•

Burned, charred or cracked insulation

•

Improperly cured varnish

•

Thrown solder

•

Flared armature windings

•

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 and wiped dry. Abnormalities identified during the inspection 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.

CAUT ION

• 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: Oil on the commutator may indicate a faulty transaxle input shaft oil seal.

Figure 16-8 Brush Rigging Removal

Figure 16-9 Retaining Ring Removal

Summary of Contents for IQ PLUS SYSTEM

Page 1: ...Club Car EDITION CODE 0906A00000 IQ PLUS SYSTEM ELECTRIC VEHICLES 2006 MAINTENANCE SERVICE SUPPLEMENT MANUAL NUMBER 102907708 ...

Page 2: ......

Page 3: ...Club Car distributor dealer representative or by a Club Car factory trained tech nician It is the policy of Club Car Inc to assist its distributors and dealers in continually updating their service knowl edge and facilities so they can provide prompt and efficient service for vehicle owners Regional technical rep resentatives vehicle service seminars periodic service bulletins maintenance and serv...

Page 4: ...mprove 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 distributors dealers and will when applicable appear in future editions of this supplement Club Car Inc reserves the right to change specifications and designs at any time without notice and without t...

Page 5: ...eshooting 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 Data from the Onboard Computer 11 46 CDM Troubleshooting Guide 11 47 SECTION 12 IQ PLUS SYSTEM DISPLAY MODULE IQDM SERIES 2 DIAGNOSTICS Plugging the Handset into the Vehicle 12 1 Introductory Display 12 2 Menu Navigation 12 2 Monitor Menu 12 4 Faults Menu 12...

Page 6: ...3 13 Receptacle Fuse Link 13 15 Battery Warning Light 13 16 SECTION 14 BATTERIES General Information 14 1 Battery Replacement 14 1 Battery Care 14 3 Preventive Maintenance 14 3 Self Discharge 14 3 Electrolyte Level 14 4 Mineral Content 14 5 Vibration Damage 14 5 Battery Charging 14 5 Charger Shuts Off After 16 Hours 14 5 Deep Discharge 14 6 Early Excessive Discharging 14 6 Incoming AC Service 14 6...

Page 7: ... 16 6 Armature Inspection and Testing 16 6 Motor Frame and Field Windings Inspection 16 7 Motor Brush Spring and Terminal Insulator Inspection 16 7 Reconditioning the Motor 16 11 Motor Assembly 16 11 Motor Installation 16 12 SECTION 17 TRANSAXLE TYPE G Lubrication 17 1 Axle Bearing and Shaft 17 1 Axle Shaft 17 1 Axle Bearing 17 4 Transaxle 17 5 Transaxle Removal 17 5 Transaxle Disassembly Inspecti...

Page 8: ...ed 18 2 M1 M2 Fast Accel 18 3 M1 M2 Pedal Up 18 3 M1 M2 Speed Cal 18 4 Code A Code B and Code C 18 5 Functions Menu 18 5 Get Settings From Controller 18 5 Write Settings to Controller 18 6 Reset All Settings 18 7 SECTION i INDEX ...

Page 9: ...d 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 maintain it could result in decreased vehicle performance or severe personal injury Any modification or change to the vehicle that affects the stability or handling of the vehicle or increases maximum vehicle speed beyond factory specifications ...

Page 10: ...per weight capacity to support 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 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 u...

Page 11: ...le not functioning correctly should be removed from use until 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 repairs and semiannual and annual periodic ser vice Figure 10 3 Battery Configuration Turf 2 Carryall 2 1 3 5 7 8 2 4 6 T O W R U N W A R N IN ...

Page 12: ...ion 14 Batteries Monthly service by owner or trained technician Batteries Wash battery tops and clean 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 compartment and underside of vehicle Semiannual service by trained technician only or every 50 hour...

Page 13: ...I P N 1012151 Brake linkage and pivots Dry Moly Lube CCI P N 1012151 Accelerator pivot rod supports Dry Moly Lube CCI P N 1012151 Charger receptacle if equipped WD 40 Brake slides Dry Moly Lube CCI P N 1012151 Front suspension 5 fittings Chassis Lube EP NLGI Grade 2 Annually by trained technician only or every 100 hours of operation whichever comes first Check fill transaxle to plug level 22 oz 0 ...

Page 14: ......

Page 15: ...s prevents the possibility of a parked vehicle with the park brake disengaged rolling away too fast to be overtaken on foot If the zero speed detect function remains engaged for two seconds or more a warning buzzer will sound to alert the driver that motor braking has been activated ý WARNING Zero speed detect will not limit vehicle speed to 1 mph 1 6 km h on very steep grades Do not operate vehic...

Page 16: ...STEM AND TESTING Wiring Diagrams Page 11 2 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement 11 WIRING DIAGRAMS Figure 11 1 Wiring Diagram Carryall 2 Turf 2 Vehicles CARRYALL 2 TURF 2 VEHICLES ...

Page 17: ...ELECTRICAL SYSTEM AND TESTING Wiring Diagrams 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11 3 11 Figure 11 2 Wiring Diagram Carryall 2 Turf 2 Vehicles ...

Page 18: ... MODE SWITCH PIN 23 GRN WHT TO RELAY COIL B PIN 10 BROWN TO FNR SWITCH FOR PIN 9 PINK TO RELAY COIL B PIN 8 GREEN TO MCOR LIMIT SWITCH SONIC WELD SONIC WELD SONIC WELD 3 PIN CONNECTOR 2 PIN CONNECTOR 3 PIN CONNECTOR SOLENOID 12 24 NEG POS REVERSE BUZZER REAR PIN 11 BLUE TO FNR SWITCH REV 1 13 18_RED_YEL W05 18_LHT_GRN W08 18_LT_BLU W11 18_ORG W12 18_GRAY W13 18_GRN W14 18_BRN W16 18_YEL W20 18_BLU...

Page 19: ...D 3 PIN CONNECTOR 4 PIN CONNECTOR FIELD ARMATURE MOTOR A1 A2 F2 F1 MODE SWITCH CIRCUIT BREAKER DASH LIGHT TOW SWITCH RELAY CHARGER CONNECTOR BLOCK TERMINAL 18_GRN_WHT W24 16_YEL W27 18_YEL W29 18_WHT W31 18_PINK W37 18_YEL_BLK_STP W38 16_TAN W44 10_BLK W39 16_TAN W52 18_PINK W15 16_LT_GREEN W49 16_PINK W50 6_RED W59 18_BLK_WHT W43 18_BRN_WHT W36 12_BLK W47 12_RED W48 14_GRAY W53 6_BLK W60 10_BLK W...

Page 20: ...ELECTRICAL SYSTEM AND TESTING Wiring Diagrams Page 11 6 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement 11 Figure 11 5 Wiring Diagram Villager 8 Vehicle VILLAGER 8 VEHICLE ...

Page 21: ...ELECTRICAL SYSTEM AND TESTING Wiring Diagrams 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11 7 11 Figure 11 6 Wiring Diagram Villager 8 Vehicle ...

Page 22: ...agnostic 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 energy units required to recharge the batteries and shuts the charger off when this number is reached 4 determines when to activate regen erative motor braking 5 locks out vehicle movement while the cha...

Page 23: ...enu 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 or connect the three pin connector to the motor speed sensor Loose or disconnected 24 pin connector at speed controller or broken wire Repair and or connect the 24 pin connector to the speed contro...

Page 24: ...23 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 24 pin connector at speed controller or broken wire Repair and or connect the 24 pin connector to the speed controller Diagnostic Menu THROTTLE FAULT 1 fault code continued Failed MCOR Test Procedure 4 MC...

Page 25: ...n operators to fully 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 require charging Place batteries on battery charger and allow them to fully charge Improperly maintained or failed batteries Section 14 Batteries Diagnostic Menu MOTOR STALL fault cod...

Page 26: ...h 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 loose wires Test Procedure 3 Solenoid Activating Coil on page 11 17 Solenoid failed coil Test Procedure 3 Solenoid Activating Coil on page 11 17 Solenoid failed solenoid diode Test Procedure 3 Solenoi...

Page 27: ...riate 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 disconnected or failed Test Procedure 14 Motor Speed Sensor on page 11 38 Vehicle will run in forward but not in reverse or will run in reverse but not forward Forward Reverse rocker switch improperly wired Te...

Page 28: ...function 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 Motor Voltage 6 Tow Run Switch 7 Circuit Breaker 8 Battery Pack Voltage Under Load 9 Key Switch and MCOR Limit Switch Circuit 10 24 Pin Connector 11 Onboard Computer Silicon Controlled Rectifier SCR Ci...

Page 29: ... 1 2 Access the 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 battery installed in reverse polarity Refer to Section 14 Batteries for further details on bat tery testing Batteries Voltage Check without the IQDM Handset 1 With batteries connected and u...

Page 30: ...le charger receptacle 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 40 43 volts If the vehicle now operates normally the DC cord has powered up the electrical system The electrical system should also power up when the accelerator pedal is pressed To check the accelerator pedal function see Test Pr...

Page 31: ... the solenoid See following NOTE 3 Place red probe of the multimeter 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 diode was removed replacement of the diode is not necessary because a diode that serves the same function is located within the speed c...

Page 32: ...SPLAY buttons 4 The IQDM should indicate 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 pedal fully pressed 5 If the MCOR does not operate as described in step 4 proceed to MCOR Voltage Test without the IQDM Handset on page 11 18 MCOR Voltage Test withou...

Page 33: ...controller 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 controller 6 With multimeter set to 20 volts DC place the black probe on battery no 8 negative post and the red probe with insulation piercing probe on the yellow wire 3 at a point close to three pin ...

Page 34: ... monitoring the multimeter 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 20k ohms connect the red probe of the multimeter to the yellow wire at the MCOR three pin connector with an insulation piercing probe Connect black probe to the white wire with an ins...

Page 35: ...e 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 Procedure 15 Solenoid Contacts on page 11 41 4 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally start ing in General Warning Section 10 Page 10 1 4 3 Check continuity on A1 and A2 motor terminal posts and continuit...

Page 36: ...ire 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 from the large post of the solenoid 2 Figure 11 16 to the two pin connector 3 Figure 11 17 at the Tow Run switch 3 Set a multimeter to 200 volts DC and with the batteries connected connect the black ...

Page 37: ...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 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 while the batteries are not under load will not always indicate th...

Page 38: ... side stringer just forward of each rear wheel See WARNING Lift only one end 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 See step 2 of Key Switch Removal Section 13 Page 13 1 4 2 Set a multimeter to 200 ohms Place the red probe on the key switch ...

Page 39: ...e MCOR See MCOR Removal Section 13 Page 13 6 TEST PROCEDURE 10 24 PIN CONNECTOR See General Warning Section 10 Page 10 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Disconnect the 24 pin connector from the speed controller Inspect terminal ends inside plug to ensure they are in position and seated in plug hou...

Page 40: ...ing so can result in a poor connection SPEED CONTROLLER 24 PIN CONNECTOR WIRE 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 Procedure 10H Pin 3 on page 11 35 Pin 4 Grey 18 gauge Test Continuity of wire Pin 5 Open no wire Test Procedure 10B Pin 2 o...

Page 41: ... 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 previous CAUTION 8 With the accelerator pedal fully up not pressed the multimeter should indicate between 5 67k ohms and 7 43k ohms 9 Slowly press the accelerator pedal while monitoring the multimeter The resistance should drop as the pedal is pressed ...

Page 42: ...Figure 11 19 Page 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 first Tighten battery terminals to 110 in lb 12 4 N m 6 Place the Tow Run switch in the RUN position 7 The multimeter should indicate zero volts DC at this time 8 While monitoring the mu...

Page 43: ...LECTRICAL SYSTEM AND TESTING Troubleshooting 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement Page 11 29 11 Figure 11 19 Test Pin 2 Light Blue Wire Detail Front of 24 Pin Connector ...

Page 44: ...ed probe of the multimeter into pin 8 green wire of 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 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 f...

Page 45: ...ery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 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 side stringer just forward of each rear wheel See WARNING Lift only one end in General Warning Section 10 Page...

Page 46: ...s under the frame crossmember between the spring mount and side 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 volts DC insert the red probe of the multimeter into pin 10 brown wire of the 24 pin connector See following CAUTION Using an alligator clip ...

Page 47: ...cate 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 check the following items Continuity of the wires in the wire harness Forward Reverse switch for proper operation See Test Procedure 16 Forward Reverse Rocker Switch on page 11 41 Tow Run switch for proper operati...

Page 48: ...t 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 terminals to 110 in lb 12 4 N m 6 With the Tow Run switch in the TOW position the multimeter should indicate zero volts 7 Place the Tow Run switch in the RUN position and the key switch in the ON posit...

Page 49: ...activity is observed 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 See Test Procedure 6 Tow Run Switch on page 11 21 Key switch for proper operation See Test Procedure 9 Key Switch and MCOR Limit Switch Cir cuit on page 11 23 Solenoid for proper operati...

Page 50: ...teries 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 probe on the charger receptacle fuse terminal that has the black 10 gauge OBC wire attached to it The reading should be approximately 36 42 volts 2 If the reading is zero volts check the black 10 gauge wire connections at the controller and receptacle Check the continu...

Page 51: ...oximately 4 0 volts before the charger relay clicks on 3 When the charger relay is activated the reading should rise to approximately 48 volts 4 If voltage does not drop to approximately 4 0 volts when the DC cord is plugged in and then rise to approximately 48 volts when the charger relay clicks on the gray wire circuit in the OBC has failed Replace the OBC TEST PROCEDURE 13 VOLTAGE AT CHARGER RE...

Page 52: ...feet 1 meter The IQDM should indicate 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 IQDM Handset Motor Speed Sensor Test without the IQDM Handset 1 Turn the key switch to the OFF position and place the Forward Reverse switch in the NEUTRAL position 2 ...

Page 53: ... controller 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 multimeter to 20 volts DC Place the black probe on the battery no 8 negative post and place the red probe on the light green wire female terminal in the three pin connector at the motor speed sensor The v...

Page 54: ...ound 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 zero to 4 85 volts and back to zero four times for each revolution of the motor armature See following NOTE NOTE The voltage reading of 4 85 is an approximate reading The actual reading may vary from ...

Page 55: ...in the NEUTRAL or REVERSE position 3 2 Place the Forward Reverse switch in the FORWARD position The IQDM should indicate that FOR WARD INPUT is ON If the IQDM indicates any other reading check vehicle wiring See Wiring Diagrams beginning on page 11 2 Also check the 24 pin connector at the speed controller See Test Procedure 10 24 Pin Connector on page 11 25 4 Test REVERSE INPUT 4 1 Access the Moni...

Page 56: ...o not touch vehicle frame 3 Place 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 4 Place the Tow Run switch in the RUN position 5 Set a multimeter to 200 volts DC Place the black probe on battery no 8 negative post and place the red probe on the red wire terminal end that was disconnected from the reverse b...

Page 57: ... 11 2 TEST PROCEDURE 19 BATTERY WARNING LIGHT See General Warning Section 10 Page 10 1 1 Reboot the OBC and drive the vehicle a short distance When vehicle is first driven the battery warning light should illuminate for 2 3 seconds See Test Procedure 18 Rebooting the Onboard Computer on page 11 43 If the battery warning light does not illuminate when rebooting the OBC proceed to step 2 2 Turn key ...

Page 58: ...ge 12 1 3 Check the FAULTS Menu 4 If a 15 RELAY DNC or 30 RELAY COIL FAULT is shown in the list a Zero Speed Detect fault has occurred Zero Speed Detect Relay Test without the IQDM Handset 1 Turn the key switch to the OFF position and place the Forward Reverse switch in the NEUTRAL position 2 Slowly push the vehicle a short distance about 3 feet 1 meter 3 You should feel resistance as motor brakin...

Page 59: ...blem 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 before being used again This data can be used to make sure all vehicles in a fleet receive equal usage on a short term basis F3 Total accumulated energy units removed since initial vehicle start u...

Page 60: ...able 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 for a value to appear in the display window 4 If a value does not appear in the display window after 30 seconds try adjusting the aim of the CDM and repeating step 3 until a value appears If there is still no reading check for weak batteries i...

Page 61: ... 32 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 instructions in the WARNING on page 11 1 After a short time replace the lead and restart the OBC OBC program is locked up Restart OBC by driving vehicle or by connecting charger DC plug OBC is in a p...

Page 62: ...11 ...

Page 63: ...rning Section 10 Page 10 1 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 P Series 2 cable 3 Find the IQDM jack located on the vehicle 4 Remove the dust cap from the IQDM jack 5 Align the keyed portion of the plug with the IQDM jack and connect the plug to the jack Figure 12 1 Connector U...

Page 64: ...2 2 Page 12 3 This button is used to navigate through and select menus Pressing the up or down arrows allows the user to scroll through the menu items When the box beside the desired menu 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 handset Figure 12 2...

Page 65: ...eries 2 handset Program The program menu allows the user to view and change custom speed controller settings See Program Menu Section 18 Page 18 2 Monitor The monitor menu displays values for certain parameters to facilitate speed controller troubleshooting See Monitor Menu on page 12 4 Faults The faults menu displays all faults recorded by the speed controller since the history was last cleared E...

Page 66: ...activated etc Since the monitor menu is updated while the vehicle is in operation the trained technician 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 ý WARNING The vehicle operator should not monitor the handset while the vehicle is in motion A technician can monitor the hands...

Page 67: ...RAL 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 indicate that the forward input is on Reverse Input With the Forward Reverse switch in the NEUTRAL or FORWARD position the handset should indicate that the reverse input is off When the Forward Reverse switch is placed in the REVERSE...

Page 68: ...n detected See Fault Descriptions on page 12 11 Main Welded Displays the number of times the MAIN WELDED fault has been detected See Fault Descriptions on page 12 11 Relay Welded Displays the number of times the RELAY WELDED fault has been detected See Fault Descriptions on page 12 11 SPD Sensor Displays the number of times the SPD SENSOR fault has been detected See Fault Descriptions on page 12 1...

Page 69: ... Displays the number of times the FLD MISSING fault has been detected See Fault Descriptions on page 12 11 HW Failsafe Displays the number of times the HW FAILSAFE fault has been detected See Fault Descriptions on page 12 11 DRVR 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 O...

Page 70: ...in the memory of the speed controller for display on the fault history menu Each detected fault is listed only once even if the fault has occurred multiple times Causes of Faults Some common causes of faults are Loose broken or disconnected wires or connectors Failed components Improper adjustment or installation of electrical or mechanical components examples brake adjust ment improper MCOR insta...

Page 71: ...nal to Zero 11 Turn off Zero Speed Detect Relay 12 Activate Zero Speed Detect function 13 Activate Zero Speed Detect beeping immediately 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 problem such as a loose wiring connection the con troller may be able to recover...

Page 72: ...tion clears 12 MAIN DROPOUT 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 16 KEY SWITCH SRO At controller power up 3 Cycle KSI 17 CURRENT SENSE FAULT KSI Off On Continuous 1 2 3 KSI Off On when condition cleared 18 M SHORTED Throttle Applied 1 2 20 DR...

Page 73: ... 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 Zero Speed Detect relay contacts are welded closed a relay welded fault is detected 09 Speed Sensor If the speed controller does not detect pulses from the speed sensor while the controller outputs power greater ...

Page 74: ...ls a precharge 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 amps a field missing fault is detected by the speed controller 23 Relay Driver On If the relay driver has been commanded to turn OFF but remains on a relay driver on fault is detected 24 HW Failsafe If the speed controller ...

Page 75: ...18 Page 18 5 See also Password Tries on page 12 5 Fault History The fault history menu can be useful in determining the cause of a vehicle problem however the fault history alone should not be the factor that determines when a component is replaced Some faults detected by the speed controller are not the result of a failed component and are instead the result of vehicle operator error If a fault a...

Page 76: ...ry of the handset and displays information pertaining to the handset PROGRAM This menu allows the user to adjust the contrast on the display screen After selecting the LCD Contrast menu use the change value buttons to adjust the contrast for the best readability FAULTS This menu selection displays faults that have been detected within the handset This faults menu does not pertain to any faults det...

Page 77: ...ging the Handset into the Vehicle on page 12 1 Vehicle batteries loose terminals or corrosion See Section 14 Batteries Vehicle batteries improperly wired See Section 14 Batteries Vehicle batteries batteries failed See Section 14 Batteries Vehicle batteries batteries not fully charged See Section 14 Batteries Handset cord has failed Test Procedure 1 Handset Cord on page 12 17 Handset cord adaptor h...

Page 78: ...racters Speed controller malfunction See Section 11 Electrical System and Testing Handset malfunction Disconnect the IQDM cord from the vehicle Wait a few seconds and reconnect the handset to the vehicle Loose connection at IQDM jack Test Procedure 3 IQDM Jacks on page 12 17 Intermittent handset cord failure Test Procedure 1 Handset Cord on page 12 17 Intermittent handset cord adaptor failure Test...

Page 79: ... 10 Page 10 1 The procedure for testing the handset cord adaptor is similar to the cord test 1 Using a multimeter set for 200 ohms place the red probe into one of the terminals on the end of the adapter with the square plug 2 Place the black probe on each of the pins one at a time on the other plug of the adaptor 3 The multimeter should indicate continuity on only one pin If any other reading is o...

Page 80: ...isconnect the four pin connectors 4 and 5 and visually inspect the contacts for damage and cor rosion Inspect the IQDM jack located on the bottom of the switch case 2 Repair and replace parts as necessary 3 3 If no problem is found connect the multi pin connectors and install the F R switch case 3 4 Install the three self tapping screws that hold the F R rocker switch case 2 to the body Tighten to...

Page 81: ...or of the speed controller 1 5 Connect the vehicle batteries positive cable first If the handset does not function during Test Procedure 3A but does function when connected directly to the speed controller the handset cord adapter and vehicle wire harness should be thoroughly tested See Test Procedure 2 Handset Cord Adaptor on page 12 17 The IQDM jacks and connections should also be thoroughly che...

Page 82: ...IQ PLUS SYSTEM DISPLAY MODULE IQDM SERIES 2 DIAGNOSTICS Test Procedures Page 12 20 2006 IQ Plus System Electric Vehicle Maintenance and Service Supplement 12 ...

Page 83: ...isconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Remove the center dash panel 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 of the center dash panel 3 2 3 Insert screw...

Page 84: ...e back of the dash panel push down on the retaining tabs surrounding the key switch 4 and remove the key switch cap 8 Hold the key switch and remove the switch retaining nut 6 from the out side of the dash panel Figure 13 2 Page 13 2 Key Switch Installation 1 Position the key switch and flat washer 9 in the center dash then install and tighten the switch retaining nut 6 to 40 in lb 4 5 N m Install...

Page 85: ...e Rocker Switch Installation 1 Press the locking tabs 11 on each end of the rocker switch and push switch into case Figure 13 3 Page 13 4 2 Connect the 18 gauge brown orange and blue wires to the rocker switch exactly as shown in the wiring diagram See Wiring Diagrams Section 11 Page 11 2 3 Install the three self tapping screws 3 that hold the Forward Reverse rocker switch case 2 to the body Tight...

Page 86: ...Page 13 4 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 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 2 Place the Tow Run switch in the TOW position and connect the battery cables p...

Page 87: ...es from the spade 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 breaker See following NOTE NOTE The spade connectors are not polarity sensitive It does not matter what color wire goes to either of the spade connectors 2 Insert the circuit breaker and ...

Page 88: ...tion 10 Page 10 1 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 only one end in General Warning Section 10 Page 10 2 3 Disconnect the two pin and three pin connectors 1 from the MCOR 2 Figure 13 5 Page 13 6 4 Remove the hex head screws 3 connecting ...

Page 89: ...pray CCI P N 1014305 to minimize corrosion 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 battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Remove center dash See step 2 of Key Switch Removal on page 13 1 3 Discon...

Page 90: ... the three push rivets 1 Figure 13 6 SOLENOID 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 17 and Test Procedure 15 Page 11 41 Solenoid Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning...

Page 91: ...nto 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 13 9 5 Install speed controller cover See Installing the Speed Controller Cover on page 13 8 6 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first T...

Page 92: ... 5 Remove black 6 gauge wire and black 10 gauge wire from the speed controller B terminal 6 Disconnect the 24 pin connector from the speed controller 7 Disconnect 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 plate 10 Slide OBC 3 towards outside of vehi...

Page 93: ...lug the 6 pin connector from the OBC into the speed controller 8 Connect the 24 pin connector to the speed controller 9 Install a wire tie to tightly secure the speed controller wires to the component mounting plate Figure 13 6 Page 13 8 10 Install the speed controller cover See Installing the Speed Controller Cover on page 13 8 11 Place the Tow Run switch in the TOW position and connect the batte...

Page 94: ...nstalling the Speed Controller Cover on page 13 8 4 Place 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 CCI P N 1014305 to minimize corrosion 5 Place the Tow Run switch in the RUN position 6 Inspect the vehicle for proper operation Make sure that the...

Page 95: ...nser tion ease of removal and good electrical contact Testing the Charger Receptacle See Test Procedure 13 Section 11 Page 11 37 See also the appropriate battery charger maintenance and service manual Charger Receptacle Inspection Inspect the receptacle for cracks loose connections and frayed wiring See following NOTE NOTE Disassembly of the charger receptacle for the purpose of removal or install...

Page 96: ...nd the receptacle backing plate Figure 13 11 Page 13 15 2 Insert receptacle into vehicle body 3 Install the four screws 2 that secure the receptacle to the vehicle body and receptacle backing plate 1 Tighten screws to 16 in lb 1 8 N m 4 Connect 18 gauge gray wire to yellow fuse holder 9 Make sure fuse 8 is installed in fuse holder 5 Connect the 10 gauge black wire to the receptacle fuse link on th...

Page 97: ...y cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 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 10 gauge black wire to the receptacle Figure 13 11 Page 13 15 3 Remove the fuse link 6 from the charger receptacle Receptacle Fuse ...

Page 98: ...age 11 43 Battery Warning Light Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Remove center dash See step 2 of Key Switch Removal on page 13 1 3 Disconnect 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 th...

Page 99: ... on or near batteries Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Ensure battery connections are clean and properly tightened See Battery Care on page 14 3 Use only 4 gauge AWG wires with low resistance terminals to replace battery wires on IQ Plus models ý WARNING See General Warning Section 10 Page 10 1 G...

Page 100: ...nt job of neutralizing and removing the corrosion Be careful not to allow the baking soda solution to enter the battery Figure 14 1 Battery Configuration Transporter 4 and 6 Carryall 6 Figure 14 2 Battery Configuration Villager 6 and 8 Figure 14 3 Battery Configuration Turf 2 Carryall 2 TRANSPORTER 4 AND 6 VEHICLES CARRYALL 6 VEHICLES FRONT OF VEHICLE Remove negative cable first Place Tow Run swit...

Page 101: ...hould be replaced or cleaned as necessary Failure to do so may cause them to overheat during operation and could result in a fire property damage or personal injury PREVENTIVE MAINTENANCE To keep batteries in sound operating condition follow these steps on a regular basis 1 Any corrosion build up on or around batteries should be removed immediately Terminal connections should be clean and tight An...

Page 102: ...o cover the plates and then charge the batteries After charging fill with water to the level indicator Filling a battery to the level indicator before charging will result in overfilling because the electrolyte level will rise during charging and some of the electrolyte may bubble out of the cap This reduces the battery s capacity and corrodes the metal parts around it The electrolyte level should...

Page 103: ...neral Warning Section 10 Page 10 1 CAUTION Only IQ Plus chargers should be used with IQ Plus vehicles Long term use of a PowerDrive battery charger with IQ Plus vehicles will damage the batteries The charger supplied with the Club Car electric vehicle resolves the most common problems associated with battery charging Undercharging and overcharging are prevented provided the charger is allowed to s...

Page 104: ...COMING AC SERVICE Make sure the incoming AC line service is sufficient If circuit breakers are tripping fuses blow during the night or the charger does not give the required starting rate when sound batteries are put on charge an AC line problem exists The electrical service to the vehicle storage facility should be sufficient to deliver adequate voltage and current to each charger with all the ch...

Page 105: ...above 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 Any reading below 5 25 V and not within 0 5 V of those batteries above 5 25 V replace battery Replace any battery with a variation of more than 50 points of specific gravity between cells or has a cel...

Page 106: ...tery no 8 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 charge voltage for the set should be between 56 0 volts and 63 0 volts depending on the age and state of charge of the batteries being tested If individual batteries read above 7 0 volts and are within 0 5 volts...

Page 107: ... 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 reading Interpreting the Results of the Hydrometer Test The approximate state of charge can be determined from the following table If the difference between the cells is 0 020 or more the low cell sh...

Page 108: ...inutes set the discharge machine to function 3 and check battery set voltage Check voltage every 10 minutes throughout the rest of the test As soon as the battery set voltage reaches 0 5 volts above the shut off point 42 0 volts use a multim eter to measure individual battery voltages Measure and record the voltage of each battery to the near est 0 01 volt See following NOTE NOTE The tester will s...

Page 109: ...es 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 5 30 V 5 30 V Battery no 4 is near end of useful life 5 40 V 5 40 V 5 00 V 5 40 V 4 60 V 5 40 V 5 40 V 5 40 V Battery nos 3 and 5 are near end of useful life ELECTROLYTE TEMPERATURE DISCHARGE TIME T...

Page 110: ...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 performance The battery charger test showed 7 0 amps after a full charge After confirming there were no problems with the electrical system charger or brakes the on charge voltage was recorded as follows Battery no 2 was imme...

Page 111: ...arger 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 C will discharge very little over a four month period Batteries stored at 80 F 26 7 C will have to be recharged every few weeks 5 48 volt Club Car electric vehicles and compatible battery chargers ar...

Page 112: ......

Page 113: ...2006 IQ Plus 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 114: ...15 ...

Page 115: ... Section 10 Page 10 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Disconnect wires from terminals on motor using two wrenches to prevent posts from turning 3 With a multimeter set to 200 ohms place black probe on motor housing Scratch through paint to ensure a good connection Place red probe on A1 A2 F1 and F...

Page 116: ...ield 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 Warning Section 10 Page 10 1 MOTOR REMOVAL 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Disconnect wires from...

Page 117: ...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 16 3 Page 16 3 9 Remove the four bolts that mount the motor to the transaxle Figure 16 20 Page 16 15 See following CAUTION ý CAUTION Do not position fingers under motor when sliding motor off of the input shaft in step 9 Fingers may get pinched when motor disengages...

Page 118: ... 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 Sensor Magnet Inspection on page 16 9 4 Orient the motor so that the splined end of the armature is facing down 5 Remove the four end cap bolts The weight of the motor housing will cause it to drop ...

Page 119: ...6 6 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 armature shaft Figure 16 7 Page 16 4 8 4 Have an assistant support the armature while the press is activated 9 Inspect the armature for wear and damage See Armature Inspection and Testing on page 16 ...

Page 120: ...aged 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 dry Abnormalities identified during the inspection can help determine original cause of failure Slight roughness of the commutator can be polished smooth with 400 grit or finer sandpaper See following...

Page 121: ...tor 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 field windings indicates the motor has overheated due to overloads or grounded or shorted coil windings If the insulation on the field windings is scorched replace the motor or the stator shell assembl...

Page 122: ... new 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 Assembly on page 16 11 When replacing brushes replace all four brushes Never replace only two Install the brushes in the same rigging 180 apart from each other Brush Inspection 1 Remove the motor from...

Page 123: ...ing 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 clean cloth to wipe the carbon dust off of the bearing Inspect the bearing by spinning it by hand and checking for both axial A and radial B play Figure 16 12 Page 16 9 4 Replace the bearing if it is n...

Page 124: ...or Component Testing and Inspection Page 16 10 2006 IQ Plus System 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 16 21 14 15 17 7 6 19 20 ...

Page 125: ...w 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 brushes in the same rigging 180 apart from each other 2 1 Insert the brushes into the brush rigging as shown 2 2 Insert the two terminal posts through insulators in the end cap 20 wall at the A1 and ...

Page 126: ...3 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 the problem MOTOR INSTALLATION See General Warning Section 10 Page 10 1 1 Clean the transaxle input shaft 1 1 Spray the input shaft thoroughly with CRC Brakleen or equivalent brake cleaner degreaser...

Page 127: ...letely 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 grease on the input shaft along the shaft toward the transaxle When the motor is pushed onto the input shaft the motor housing will not bottom out against the transaxle housing There will be approx...

Page 128: ...rect 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 and blue wires with a wire tie so that none of the motor wires will scrub the motor or transaxle when the vehicle is in operation 3 10 Connect the three pin speed sensor plug to the vehicle wire har...

Page 129: ...tch in the RUN position 11 Inspect the vehicle for proper operation See following WARNING ý WARNING Make sure that the vehicle operates in the forward direction when the Forward Reverse switch is in the FORWARD position Make sure that the vehicle operates in the reverse direction when the Forward Reverse switch is in the REVERSE position The reverse buzzer will sound as a warning when the Forward ...

Page 130: ...16 ...

Page 131: ...and Oil Seal Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Place chocks at the front wheels Loosen lug nuts on rear wheels and lift the rear of the vehicle with a chain hoist or floor jack Place jack stands under the axle tubes to support the vehicle See WARNING Lift only one end in General Warning Sect...

Page 132: ...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 shoulder on the axle shaft 8 Inspect bearing 5 Figure 17 5 Page 17 3 If the bearing in a Type G transaxle is worn or damaged the entire axle shaft assembly 1 or 2 must be replaced Figure 17 1 Axle Tube Figure...

Page 133: ...us 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 3 8 36 27 30 28 37 38 5 6 4 15 39 TYPICAL 6 PLACES ...

Page 134: ... 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 gear 27 Figure 17 5 Page 17 3 Continue advancing the shaft until the bearing on the axle is firmly seated within the axle tube hub seat 2 2 Use a pair of snap ring pliers to install the retaining ring 6...

Page 135: ...t 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 Remove the rear wheels then thread one lug nut onto a stud on each rear hub This will keep the brake drums on the hubs 4 Remove the bow tie pins 1 brake cable clevis pins 2 and cable retaining E clips ...

Page 136: ...or 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 becomes disengaged from the input shaft then lift motor out See preceding WARNING 11 If a floor jack was used pull floor jack from beneath the transaxle and allow the springs to rest on the floor 1...

Page 137: ...parating 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 5 Page 17 3 See following CAUTION CAUTION Do not damage gears Use extreme care when handling them 5 Use a bearing puller or arbor press to remove bearings 16 from the input pinion gear If the oil s...

Page 138: ...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 holding the unit slightly above the work area lightly tap the bolt heads Figure 17 14 Page 17 8 Remove the two bolts 8 4 Remove the differential pin 31 by pushing pin through differential gear case from one side...

Page 139: ...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 of the pin 2 2 Install the hex bolts 33 and output gear 32 Tighten bolts to 58 ft lb 78 6 N m 3 Press a new bearing 18 onto the intermediate gear assembly Figure 17 5 Page 17 3 4 Press new bearing 16 onto inp...

Page 140: ...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 0 090 tip CCI P N 1012560 attach the internal retaining ring into the axle tube hub so that it seats against the axle bearing assembly and into the machined slot in the inside wall of the axle tube hub...

Page 141: ...ring 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 lb 20 3 N m 8 Connect the brake cables using new bow tie pins 1 Figure 17 7 Page 17 5 9 Install the shock absorbers Tighten shock absorber retaining nuts until the rubber bushings expand to the same ...

Page 142: ...17 ...

Page 143: ...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 P Series 2 cable 3 Find the IQDM jack located below the Forward Reverse switch 4 Remove the dust cap from the IQDM jack located on the vehicle below the Forward Reverse switch 5 Align the keyed portion of the plug with the IQDM jack and connect the pl...

Page 144: ... the program 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 Mode 2 are programmed with the same procedues as Mode 1 M1 M2 SPEED The vehicle s top speed can be changed by selecting values 1 through 4 See chart below A vehicle programmed for speed setti...

Page 145: ... accelerator pedal is released motor brak ing will slow the vehicle to a speed of approximately 11 mph 17 7 km h 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 pedal is released See following NOTE Change the settings of the M1 M2 Pedal Up by pressing or on the change value button NOTE M1 M2 pedal up does...

Page 146: ...18 0 km 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 9 mph 11 1 km h 10 9 mph 17 5 km h 13 9 mph 22 4 km h 15 9 mph 25 6 km h 12 6 8 mph 10 9 km h 10 8 mph 17 4 km h 13 8 mph 22 2 km h 15 8 mph 25 4 km h 13 6 7 mph 10 8 km h 10 7 mph 17 2 km h 1...

Page 147: ...echnician to clone a speed controller Once the speed controller settings have been transferred to the handset the technician can then connect the handset to another vehicle and transfer the stored settings into the speed controller Speed Controller Cloning Transferring Settings from the Vehicle to the Handset 1 Locate a vehicle that has the desired speed controller settings 2 Turn the key switch t...

Page 148: ...ed Con troller Cloning Transferring Settings from the Vehicle to the Handset on page 18 5 2 Locate a vehicle that does not have the desired speed controller settings 3 Turn the key switch to the OFF position place the Forward Reverse handle in the NEUTRAL position and lock the park brake 4 Plug the handset into the vehicle 4 1 Connect one end of the cable to the jack located on the bottom of the h...

Page 149: ...ill work correctly only when the handset has not been unplugged and power to the speed controller has not been interrupted Resetting All Settings 1 During an active session when the settings need to be returned to the original values the values that were active at the beginning of the session scroll to the functions menu and select 2 Select settings 3 Select reset all settings 4 Press on the chang...

Page 150: ...18 ...

Page 151: ...st 14 8 battery warning light installation 13 16 removal 13 16 testing 11 43 bearing axle see transaxle type g axle bearing bearing motor see motor bearing braking motor see regenerative braking braking regenerative see regenerative braking C charger receptacle fuse link 13 15 installation 13 15 removal 13 15 installation 13 14 removal 13 13 testing 11 37 circuit breaker installation 13 5 circuit ...

Page 152: ...econditioning 16 11 removal 16 2 service specifications 16 11 speed sensor testing 11 38 speed sensor magnet inspection 16 9 testing 11 21 see test procedures motor zero speed detect 11 1 motor braking see regenerative braking motor controller output regulator MCOR installation 13 7 removal 13 6 testing 11 18 11 23 O onboard computer OBC 11 8 installation 13 10 rebooting 11 43 removal 13 10 retrie...

Page 153: ... 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 16 2 armature ground test 16 7 Tow Run switch 11 8 installation 13 4 13 5 removal 13 4 13 5 testing 11 21 transaxle type g assembly 17 9 axle bearing 17 4 axle shaft installation 17 4 removal 17 1 disassembly 17 7 inspection 17 7 installation 17 10 lubrication 17 1 ...

Page 154: ...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 publication in the following catgories Your Comments Are Appreciated Please select y our ca tegory Distributor Dealer Individual Owner Club Car Associate Representative Technician Golf Course Superintendent Oth...

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