Club Car Precedent 2004 Maintenance And Service Download Page 206

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INDEX

Page i--4

2004 Precedent IQ System Golf Car Maintenance and Service Manual

testing ............................................................ 11-39

solenoid activating coil

testing ............................................................ 11-20

speed controller

connector, 16-pin

see

test procedures

installation ...................................................... 12-11

removal .......................................................... 12-11

speed sensor

see

motor, speed sensor

steering

rack and pinion

assembly ....................................................... 7-8

disassembly .................................................. 7-7

installation ..................................................... 7-9

removal ......................................................... 7-4

steering column

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

disassembly ....................................................... 7-4

installation .......................................................... 7-4

removal .............................................................. 7-2

steering wheel

installation .......................................................... 7-2

removal .............................................................. 7-1

storage

electric vehicle ................................................... 3-2

stress lines

see

repair, front and rear body

suspension, front

camber adjustment .......................................... 7-10

components

control arm

installation .............................................. 7-17
removal ................................................... 7-14

kingpin and steering spindle

installation .............................................. 7-13
removal ................................................... 7-13

leaf spring

installation .............................................. 7-13

leaf spring removal ...................................... 7-13

shock absorber

installation .............................................. 7-17
removal ................................................... 7-17

tie rod

installation .............................................. 7-12

tie rod end

removal ................................................... 7-12

wheel bearings and hub

inspection ............................................... 7-17
installation .............................................. 7-18
removal ................................................... 7-17

lubrication ........................................................ 7-10

toe-in adjustment ............................................. 7-11

wheel alignment ............................................... 7-10

suspension, rear

leaf spring

installation ..................................................... 9-4

removal ......................................................... 9-1

shock absorber

inspection and removal ................................. 9-1

installation ..................................................... 9-1

test procedures

1 – batteries/voltage check ............................ 11-18

2 – onboard computer solenoid lockout circuit 11-19

3 – solenoid activating coil ............................. 11-20

3 – solenoid diode .......................................... 11-20

4 – MCOR ...................................................... 11-21

5 – motor, A1 and A2 voltage ........................ 11-22

6 – Tow/Run switch ....................................... 11-23

7 – battery pack voltage (under load) ............ 11-24

8 – key switch ................................................ 11-24

8 – MCOR limit switch ................................... 11-24

9 – 16-pin connector ...................................... 11-26

10 – onboard computer SCR ......................... 11-36

11 – OBC gray wire and fuse ......................... 11-37

12 – charger receptacle ................................. 11-37

13 – speed sensor, motor .............................. 11-38

14 – solenoid ................................................. 11-39

15 – Forward/Reverse rocker switch ............. 11-40

16 – reverse buzzer ....................................... 11-41

17 – OBC, rebooting ...................................... 11-41

18 – battery warning light ............................... 11-42

test procedures, motor

1 – internal short circuits .................................. 15-1

2 – armature circuit open ................................. 15-2

3 – field circuit open ......................................... 15-2

armature ground test ....................................... 15-6

tie rod and drag link

installation ........................................................ 7-12

removal ............................................................ 7-10

tire

installation .......................................................... 8-3

removal .............................................................. 8-2

repair .................................................................. 8-2

Tow/Run switch

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

installation ........................................................ 12-6

removal ............................................................ 12-6

testing ............................................................ 11-23

transaxle, type g

assembly ...................................................... 16a-10

axle bearing ................................................... 16a-5

axle shaft

installation ................................................. 16a-4

removal ..................................................... 16a-1

Summary of Contents for Precedent 2004

Page 1: ...2004 Maintenance And Service Manual No 102397619 Edition Code 1203D0205C IQ System Electric Vehicles ...

Page 2: ......

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

Page 4: ... and other products These improvements may affect servicing procedures Any modification and or significant change in specifications or proce dures will be forwarded to all Club Car dealers and will when applicable appear in future editions of this manual Club Car Inc reserves the right to change specifications and designs at any time without notice and without the obligation of making changes to u...

Page 5: ...t 4 1 Front and Rear Body Repair 4 2 Stress Lines or Streaks 4 2 Minor Impact Damage Deformations 4 2 Minor Scratches and Surface Blemishes 4 2 Gouges Punctures Tears Large Scratches and Abrasions 4 2 Front Body 4 3 Front Body Removal 4 3 Front Body Installation 4 3 Front Bumper 4 5 Floor Mat and Retainers 4 6 Floor Mat Retainer Removal 4 6 Floor Mat Retainer Installation 4 6 Kick Plate and Charge...

Page 6: ...l 6 1 Brake Assembly Cleaning 6 5 Brake Shoe Installation 6 6 Brake Cable Equalizer Adjustment 6 8 Brake Cluster Removal and Installation 6 9 Brake Cluster Installation 6 10 Brake Cable Removal and Installation 6 11 SECTION 7 STEERING AND FRONT SUSPENSION General Information 7 1 Steering Wheel 7 1 Steering Wheel Removal 7 1 Steering Wheel Installation 7 2 Steering Column 7 2 Steering Column Remova...

Page 7: ...nd Hubs 7 17 Front Wheel Free Play Inspection 7 17 Front Hub Removal 7 17 Hub Installation 7 18 SECTION 8 WHEELS AND TIRES General Information 8 1 Wheels 8 1 Wheel Removal 8 1 Wheel Installation 8 1 Tires 8 1 Tire Removal 8 2 Tire Repair 8 2 Tire Installation 8 3 SECTION 9 REAR SUSPENSION General Information 9 1 Shock Absorbers 9 1 Shock Absorber Removal and Inspection 9 1 Shock Absorber Installat...

Page 8: ... Procedures 11 17 Index of Test Procedures 11 18 Communication Display Module CDM 11 42 Using the CDM to Retrieve Data from the Onboard Computer 11 43 CDM Troubleshooting Guide 11 44 SECTION 12 ELECTRICAL COMPONENTS Key Switch 12 1 Battery Warning Light 12 3 Forward Reverse Rocker Switch 12 4 Electronics Module Cover 12 5 Tow Run Switch 12 6 Motor Controller Output Regulator MCOR 12 7 Reverse Buzz...

Page 9: ...esting 13 9 Battery Charger Test 13 9 On Charge Voltage Test 13 9 Hydrometer Test 13 9 Discharge Test 13 11 Battery Troubleshooting Examples 13 13 Battery Storage 13 14 Charging a Battery Pack that has Low Voltage 13 14 SECTION 14 BATTERY CHARGER SECTION 15 MOTOR General Information 15 1 External Motor Testing 15 1 Motor 15 3 Motor Component Testing and Inspection 15 5 Armature 15 5 Field Windings...

Page 10: ...l 16a 5 Transaxle Disassembly Inspection and Assembly 16a 7 Transaxle Disassembly and Inspection 16a 7 Transaxle Assembly 16a 10 Transaxle Installation 16a 11 SECTION 16B TRANSAXLE TYPE K Transaxle Identification 16b 1 Lubrication 16b 1 Axle Bearing and Shaft 16b 1 Axle Shaft 16b 1 Axle Bearing 16b 4 Transaxle 16b 6 Transaxle Removal 16b 6 Transaxle Disassembly Inspection and Assembly 16b 8 Transa...

Page 11: ...UTION with the safety alert symbol indicates a hazard or unsafe practice that could result in minor personal injury CAUTION A CAUTION without the safety alert symbol indicates a potentially hazardous situation that could result in property damage GENERAL WARNINGS The following safety statements must be heeded whenever the vehicle is being operated repaired or ser viced Other specific safety statem...

Page 12: ...d factory specifications could result in severe personal injury or death Check the vehicle for proper location of all vehicle safety and operation decals and make sure they are in place and are easy to read Wear safety glasses or approved eye protection when servicing the vehicle or battery charger Wear a full face shield and rubber gloves when working on or near batteries Do not wear loose clothi...

Page 13: ... release park brake BODY CHASSIS Frame Chassis Aluminum and composite Front and rear body Dupont Surlyn Reflections Body finish High gloss molded in color Tires 18 x 8 5 8 tubeless 4 ply rated DIMENSIONS WEIGHT Overall length 91 5 in 232 cm 104 in 264 cm Overall width 47 25 in 120 cm 47 25 in 120 cm Overall height with canopy 68 5 in 174 cm 71 in 180 cm Overall height at steering wheel 48 0 in 122...

Page 14: ...2 ...

Page 15: ...ecific to their vehicle s Refer to the owner s manual provided with the vehicle for information on the following topics Pre Operation and Daily Safety Checklist Controls and Indicators Driving Instructions Towing Transporting on a Trailer Subsequent Owner Registration Warranties SERIAL NUMBER IDENTIFICATION The serial number of the vehicle is printed on a bar code decal mounted on the passenger si...

Page 16: ...orced The safety committee should include all these items and such others as the committee feels necessary or appropriate STORAGE See General Warnings Section 1 Page 1 1 WARNING Turn the key switch OFF remove the key and leave the Forward Reverse switch in the NEUTRAL position during storage This is to prevent unintentionally starting the vehicle or a fire hazard Do not attempt to charge frozen ba...

Page 17: ... vehicle from rolling 8 Keep batteries fully charged during storage Chargers Leave chargers plugged in during storage The onboard computer will automatically activate the charger when necessary If the battery charger is left plugged in during extended storage the elec trolyte should be checked monthly to ensure that proper level is maintained AC power should also be checked periodically If charger...

Page 18: ...3 ...

Page 19: ... components can result in water damage and subsequent component failure Use non abrasive wax products Do not use abrasive leveling or rubbing compounds these will permanently dull the gloss Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately to prevent possible stains NOTE Dispose of waste water properly SEAT To preserve seat appearance clean regularly...

Page 20: ...r to the one used to remove stress lines To remove deformations resulting from minor impact damage 1 Hold a heat gun 12 inches 30 cm away from the affected area with the gun on its lowest heat setting 2 Periodically remove the heat gun and bend the body using a push block in the opposite direction of the deformation 3 Continue heating and bending the body until the original shape returns Under no ...

Page 21: ...ap tabs 3 If the vehicle is equipped with a canopy loosen the canopy support cover then loosen but do not remove the front canopy support bolts If there is no canopy remove the non canopy cover 4 Remove the five screws 8 and lift the brow and fascia assembly 4 from the front underbody 5 Remove the five screws 7 to separate the front fascia 6 from the brow 5 FRONT BODY INSTALLATION 1 Install fascia...

Page 22: ...BODY AND TRIM Front Body Page 4 4 2004 Precedent IQ System Golf Car Maintenance and Service Manual 4 Figure 4 1 Front Body 3 8 TYPICAL 5 PLACES 2 1 5 6 7 TYPICAL 4 PLACES TYPICAL 5 PLACES 4 ...

Page 23: ...ecure brow cap 1 with four screws 2 Tighten screws to 3 3 ft lb 4 5 N m FRONT BUMPER The underbody bracket 1 connects the front suspension to the front underbody Figure 4 2 Page 4 5 Each bracket is secured in place by two taptite screws 2 tightened to 13 ft lb 17 6 N m The front bumper 3 is attached to the vehicle frame rails by nuts 5 and bolts 4 The nuts 5 need to go on top of the bumper attachi...

Page 24: ...igure 4 3 Page 4 6 2 Remove screw 4 from lower rear corner of retainer This screw threads into a J clip 5 that is attached to the rear underbody 3 Carefully pull on retainer to separate the trim clips from their respective slots Trim clips do not normally need to be removed from the retainer FLOOR MAT RETAINER INSTALLATION 1 Position the retainer on the vehicle and press firmly to engage the trim ...

Page 25: ...ehicle 4 Remove the two front screws 3 that hold the beauty panel to the vehicle Raise the forward portion of the rear beauty panel to disengage it from the tabs on the upper portion of the kick plate 5 Remove kick plate from vehicle KICK PLATE AND CHARGER BEZEL INSTALLATION 1 Position the kick plate 2 on the vehicle and secure with three screws 1 Figure 4 4 Page 4 8 Ensure front lower edge of rea...

Page 26: ...ESSORY MOUNTING The Structural Accessory Module SAM includes two threaded inserts on both the driver side and the pas senger side Figure 4 5 Page 4 9 These inserts serve as common attachment points for various accessor ries Accessories that can be mounted to the SAM include single or dual sand bottles sand bucket and the club cleaner Figure 4 4 Kick Plate 1 4 2 3 ...

Page 27: ...acing the backrest tighten screws 2 to 5 9 ft lb 8 N m Bag Rack Removal 1 Remove two screws 10 to release the bag hoop 6 and related components from the SAM 3 Figure 4 6 Page 4 10 2 Bag strap 8 may be released by removing two plastic barrel connectors 9 and one screw 12 3 Bag strap buckles 7 may be snapped out of bag hoop 6 Bag Rack Installation Installation is the reverse of removal Tighten screw...

Page 28: ...ody Page 4 10 2004 Precedent IQ System Golf Car Maintenance and Service Manual 4 Figure 4 6 Backrest and SAM Disassembly 10 TYPICAL 2 PLACES 6 7 8 5 12 9 9 12 11 2 3 4 1 TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES 7 ...

Page 29: ... 13 Tighten screws to 3 7 ft lb 5 N m 2 Connect the three wires to the switch 16 in the order shown 3 Position the housing 15 on the front of beauty panel 12 and secure with two screws 14 Tighten screws to 20 in lb 2 3 N m 4 Position canopy support brackets 1 and 2 on vehicle and secure each with one screw 3 Tighten screws to 6 6 ft lb 9 N m 5 Position the SAM on the vehicle See SAM Installation o...

Page 30: ...the upper portion of each support 19 and 20 Figure 4 7 Page 4 13 2 Remove one screw 22 from the lower portion of each support 19 and 20 Remove supports from vehi cle 3 Remove bolts 10 to release liners 8 and 9 from vehicle Wheel Liner Installation 1 Position liners 8 and 9 on vehicle and secure with bolts 10 Bolts 10 thread into J clips 11 attached to the inner frame rail Tighten bolts to 4 4 ft l...

Page 31: ...dy 2004 Precedent IQ System Golf Car Maintenance and Service Manual Page 4 13 4 Figure 4 7 Rear Body Disassembly 13 16 TYPICAL 4 PLACES 14 2 3 1 5 4 5 7 6 8 21 20 22 9 18 11 11 19 22 21 10 10 12 15 BODY CLIPS RED WHITE BLUE ...

Page 32: ...screw 4 on top of instrument panel 3 Figure 4 8 Page 4 14 2 Tilt instrument panel up to release it from the dash assembly 1 3 Disconnect the electrical connector on the passenger side of the instrument panel 3 and remove the panel 4 Remove two barrel fasteners 7 to release dash tray 6 5 Remove three screws 2 and remove dash assembly 1 from vehicle Figure 4 8 Dash Assembly 1 2 3 4 7 6 TYPICAL 3 PLA...

Page 33: ... lb 12 N m 2 Position dash tray 6 in dash and secure with two barrel fasteners 7 3 Install the instrument panel 3 1 Connect the electrical connector on the instrument panel to the harness connector 3 2 Position the instrument panel 3 on the dash assembly Make sure tabs on upper edge properly engage with the corresponding slots on the dash assembly Ensure that there are no wires exposed or pinched ...

Page 34: ...4 ...

Page 35: ...P REMOVAL 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Remove screws 1 Pull floor mat retainer 3 away from the vehicle Figure 5 1 Page 5 1 3 Pull floor mat 2 over the pedal group to gain access to the pedal group hardware 4 Lift off cover plate 7 Figure 5 2 Page 5 2 5 Loosen jam nuts 4 and 5 on each side of tur...

Page 36: ...ATOR AND BRAKE PEDAL GROUP Pedal Group Page 5 2 2004 Precedent IQ System Golf Car Maintenance and Service Manual 5 Figure 5 2 Pedal Group 2 TYPICAL 2 PLACES 1 TYPICAL 2 PLACES 3 ELECTRICAL CONNECTIONS 6 4 5 7 ...

Page 37: ...he Precedent electric vehicle includes a Motor Controller Output Regulator MCOR mounted on the side of the pedal group The MCOR detects the position of the GO pedal and sends a corre sponding voltage to the motor controller DEBRIS SHIELDS Debris shields on the top face of the pedal group prevent excessive debris from contacting the moving parts of the pedal group Both shields 3 and 4 are held in p...

Page 38: ...ecured by two crosspins Figure 5 4 Page 5 5 The assembly is replaced as a unit The replacement unit includes a pin that keeps the spring compressed so it can be installed in the pedal group Replace the assembly as follows CAUTION Spring is under tension Use caution when working with springs 1 With the pedal group removed from the vehicle and debris shield removed remove the accelerator return spri...

Page 39: ...LERATOR AND BRAKE PEDAL GROUP Pedal Group 2004 Precedent IQ System Golf Car Maintenance and Service Manual Page 5 5 5 Figure 5 4 Brake Pedal 1 2 3 4 5 7 8 6 10 7 9 OPPOSITE SIDE VIEW 11 12 Typical 3 places ...

Page 40: ... two screws 2 on the driver side and two screws 1 on the passenger side Tighten driver side screws 2 to 12 ft lb 16 3 N m Tighten passenger side screws 1 to 5 ft lb 6 8 N m 4 Use the turnbuckle 6 to connect the rod from the pedal group to the brake actuator rod Ensure the ends of the brake cables do not slip out of the brake equalizer during this procedure 5 Adjust the brake cable equalizer tensio...

Page 41: ... Group 2004 Precedent IQ System Golf Car Maintenance and Service Manual Page 5 7 5 7 Install the floor mat 2 over the pedal group Make sure tabs on floor mat sides are beneath the sill 3 Tighten screws 1 to 53 in lb 6 N m Figure 5 1 Page 5 1 ...

Page 42: ...5 ...

Page 43: ...bles as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Place chocks at the front wheels Loosen but do not remove lug nuts on rear wheels and lift the rear of the vehicle with a chain hoist or floor jack Place jack stands under the axle tubes to support the vehicle 3 Gain access to the pedal group by removing the floor mat and access panel See Peda...

Page 44: ...lease the shoes from the backing plate allowing them to pivot away from the inside of the brake drum which should then allow the brake drum to be pulled free After completing step 8 skip step 9 NOTE Although step 8 allows easier access to the brake shoes it is not imperative to do so in order to remove the brake shoes 8 Remove the axle 8 1 Using 90 snap ring pliers CCI P N 1012560 remove the axle ...

Page 45: ...Removal 2004 Precedent IQ System Golf Car Maintenance and Service Manual Page 6 3 6 Figure 6 4 Self adjusting Wheel Brake Assembly 10 TYPICAL 4 PLACES 1 8 6 9 4 3 2 13 12 6 5 7 TYPICAL 2 PLACES 7 TYPICAL 2 PLACES 11 TYPICAL 4 PLACES 15 ...

Page 46: ...The brake shoes are under pressure and can release suddenly when brake shoe retainers are removed 10 Grasp both brake shoes and pull them together with the springs out of the brake assembly as shown Figure 6 6 Page 6 4 11 Remove adjuster wheel 1 with two washers 2 and 3 from the backing plate Figure 6 7 Page 6 4 Figure 6 5 Remove Shoe Retainer Clip Figure 6 6 Remove Brake Shoes Figure 6 7 Remove A...

Page 47: ...uld cause diminished brake performance possibly resulting in property damage or severe personal injury 4 Use a small brush to carefully apply a light coat of white lithium NLGI 2 grease Dow Corning BR2 Plus or equivalent on each of the six raised bosses on the brake backing plate Figure 6 9 Page 6 5 See preceding WARNING 5 Use a small brush to carefully apply a light coat of white lithium NLGI 2 g...

Page 48: ...marked 17T should be facing out and be visible On the driver side the 17L on the leading shoe should be facing out and be visible When installed on the backing plate the leading shoe stamped 17L is always oriented toward the rear of the vehicle 2 Install the shoe retainer clip using pliers to compress the clip 1 while turning the retainer pin 2 into position Figure 6 13 Page 6 6 3 Attach the sprin...

Page 49: ...d until it stops Figure 6 17 Page 6 7 Remove the screw driver 7 Install the rear axle onto the transaxle See following NOTE NOTE There is a LEFT and RIGHT side axle The splined portions on the axles that insert into the trans axle case are two different lengths The longest length spline is the LEFT or driver side axle 7 1 Insert the splined end of the axle shaft into the axle tube Be careful not t...

Page 50: ... in the mounting slots 9 After the drum is installed make sure the axle and drum turn freely and then install the wheel SeeWheel Installation Section 8 Page 8 1 10 Adjust brake cable equalizer See Brake Cable Equalizer Adjustment on page 6 8 BRAKE CABLE EQUALIZER ADJUSTMENT See General Warnings Section 1 Page 1 1 See also Warning on Page 6 1 1 After maintenance on the the brake system is complete ...

Page 51: ... turnbuckle 2 Figure 6 1 Page 6 2 Note that the forward jam nut 1 is a left hand thread Thread each nut approximately 1 2 inch 12 7 mm away from the turnbuckle 5 Loosen turnbuckle 2 to release tension on the equalizer bracket 4 that pulls on the heads of the brake cables 6 Remove lug nuts and rear wheels and then the brake drums NOTE When servicing vehicles with self adjusting brakes with badly wo...

Page 52: ...of the axle shaft into the axle tube Be careful not to damage the seal on the inside of the axle tube hub Advance the shaft through to the bearing on the shaft and rotate it to align the shaft splines 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 4 2 Using 90 internal snap ring pliers 0 090 t...

Page 53: ...e turnbuckle 5 Loosen turnbuckle 2 until the lag bolt 5 is free of the turnbuckle 6 Rotate the lag bolt 5 and equalizer bracket 4 to the upright position then slip the cable heads out of the bracket 7 Remove nut 1 from the bolt 2 that secures front of the leaf spring Figure 6 21 Page 6 12 Do not remove bolt 2 8 Remove the mounting tab 3 of the brake cable from the bolt 9 Using brake cable release ...

Page 54: ...acket 4 in the upright position and slip the cable head through the hole on top of the bracket Pivot the equalizer to the horizontal position to capture the cable heads in the equalizer 3 Insert the rear cable housing into the shock mount bracket 4 Figure 6 20 Page 6 12 Push the cable housing end into the bracket to ensure the clips on the housing end secure the cable in position 4 At the rear whe...

Page 55: ... 1 Figure 7 3 Page 7 3 3 Match mark the steering wheel 7 and steering column shaft 9 so when the steering wheel is removed it can be placed back in exactly the same position on steering column shaft 4 Loosen the steering wheel bolt 6 and back it off approximately 1 4 inch 6 mm Do not remove the bolt 5 If it is difficult to remove the steering wheel use the steering wheel puller CCI P N 102061201 t...

Page 56: ...Be sure to align the match marks placed on the wheel and steering column in step 3 above Figure 7 3 Page 7 3 2 Install the steering wheel bolt 6 and tighten to 13 ft lb 17 6 N m 3 Install the scorecard plate 1 and plate mounting screws 8 Figure 7 3 Page 7 3 Tighten screws to 16 in lb 1 8 N m STEERING COLUMN See General Warnings Section 1 Page 1 1 STEERING COLUMN REMOVAL 1 Disconnect the battery ca...

Page 57: ...STEERING AND FRONT SUSPENSION Steering Column 2004 Precedent IQ System Golf Car Maintenance and Service Manual Page 7 3 7 Figure 7 3 Steering Column 1 4 5 6 3 2 7 9 11 13 10 12 8 ...

Page 58: ...al joint through the front underbody Position uni versal joint over splined stud on the steering gear Leave bolt 11 loose until steering column is mounted to frame in step 3 Figure 7 3 Page 7 3 3 Align the holes in the steering column mounting bracket with holes in the vehicle frame Secure column to frame with four bolts 10 Tighten bolts to 18 4 ft lb 25 N m 4 Tighten universal joint bolt 11 to 18...

Page 59: ...k and pinion is reassembled Use a plastic wire tie to secure the dust seal bellows 3 Remove the two hex nuts 11 and slide off both of the dust seal bellows 9 from ball joints 8 4 Remove rack screw nut 14 rack guide screw 13 rack guide pressure spring 15 and the rack guide 16 5 Remove the universal joint assembly from the pinion 5 by removing the bolt and then sliding off the uni versal joint 6 Rem...

Page 60: ...ND FRONT SUSPENSION Rack and Pinion Page 7 6 2004 Precedent IQ System Golf Car Maintenance and Service Manual 7 Figure 7 5 Steering Gear 1 2 4 3 5 6 7 18 8 8 17 21 21 16 15 14 13 9 9 10 10 11 11 12 19 20 12 19 20 ...

Page 61: ...Page 7 7 11 Inspect the bushing 7 and needle bearing 6 for excessive wear If wear is excessive replace the entire assembly Figure 7 5 Page 7 6 12 Inspect the ball joints 8 for wear If one or both of the ball joints 8 are excessively worn remove and replace the ball joint from the rack 18 13 Remove the rack 18 from housing 17 Figure 7 6 Remove Dust Seal Figure 7 7 Pinion Snap Rings Figure 7 8 Remov...

Page 62: ...5 Page 7 6 7 Install the ball joints 8 onto the rack 18 by securing the rack in a vise using wood blocks between the rack and the jaws of the vise to protect the rack from damage Tighten the ball joints to 60 ft lb 81 N m 8 Tap a flange into the notch on the rack Figure 7 11 Page 7 9 9 Place a few drops of Loctite 222 to the threads of the screw 14 Figure 7 5 Page 7 6 10 Install the rack guide 16 ...

Page 63: ...ition the assembly over the mounting holes and slide the universal joint over the square end of the steering column 4 Install three screws to secure the assembly to the vehicle Tighten screws to 22 ft lb 30 N m 5 Install the tie rod ends 3 into the left and right hand spindle tabs 4 and then install the retaining nuts 2 Figure 7 4 Page 7 5 See following WARNING WARNING Do not operate vehicle until...

Page 64: ...necessary Camber Adjustment 1 Check each front wheel with a framing square At the floor or ground there should be an equal amount of space between each tire and the framing square Figure 7 14 Page 7 11 2 Loosen do not remove the four bolts 17 that secure the leaf spring 13 to the bottom spring plate 16 Figure 7 19 Page 7 16 See also Figure 7 15 Page 7 11 3 Loosen do not remove the hex nut 8 on the...

Page 65: ...should be even with the bottom surfaces of the vehicle frame 3 Measure the distance between the marks on the rear facing surfaces of the tires and then roll the vehicle forward one and one half wheel revolution until the marks appear on the forward facing surfaces of the tires at about the same height from the floor Figure 7 16 Page 7 11 4 Measure the distance between the marks on the forward faci...

Page 66: ... the steering wheel should be at the center of its travel There should be equal travel to the left and right FRONT SUSPENSION COMPONENTS See General Warnings Section 1 Page 1 1 TIE ROD END REMOVAL 1 Loosen jam nuts 13 to allow later rotation of the tie rod ends 12 Figure 7 18 Page 7 15 2 Remove the retaining pins 15 and retaining nuts 14 3 Lift tie rod ends from the spindle tabs 4 Remove the tie r...

Page 67: ...ish tightening lug nuts using a crisscross pattern to 55 ft lb 74 6 N m 6 Adjust camber and toe in See Wheel Alignment on page 7 10 KINGPIN AND STEERING SPINDLE REMOVAL 1 Remove the front hub See Front Hub Removal on page 7 17 2 Remove cotter pins 15 and nuts 14 then remove tie rod ends 12 from the tabs on the spindles Figure 7 18 Page 7 15 3 Remove the nut 1 and washer 2 from the top of the kingp...

Page 68: ...l front hub and wheel See Hub Installation on page 7 18 CONTROL ARM REMOVAL 1 Loosen lug nuts on both front wheels and raise front of the vehicle with a chain hoist or floor jack Place jack stands under the front aluminum rails of the vehicle frame and lower the vehicle onto the jack stands 2 Remove wheel 3 Remove bolts 17 and move rack and pinion to allow clearance for bolt 19 Figure 7 18 Page 7 ...

Page 69: ...NT SUSPENSION Front Suspension Components 2004 Precedent IQ System Golf Car Maintenance and Service Manual Page 7 15 7 Figure 7 18 Upper Front Suspension Assembly 4 8 11 10 2 3 5 6 7 9 6 4 3 1 2 14 15 13 12 16 17 19 18 ...

Page 70: ... SUSPENSION Front Suspension Components Page 7 16 2004 Precedent IQ System Golf Car Maintenance and Service Manual 7 Figure 7 19 Lower Front Suspension Assembly 1 3 4 2 5 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 3 CLEVIS ...

Page 71: ...moval procedure 2 Tighten the bolts to 20 ft lb 27 N m FRONT WHEEL BEARINGS AND HUBS See General Warnings Section 1 Page 1 1 NOTE The front wheel bearings are pressed into the spindle and are not serviceable If excessive free play is detected the entire hub should be replaced FRONT WHEEL FREE PLAY INSPECTION 1 Raise the front of the vehicle 2 Use your hands to attempt to rock the wheel and hub ass...

Page 72: ...tate the hub The hub should rotate smoothly without binding side play or any indication of rough spots during rotation 5 Install the dust cap 12 using a rubber mallet and tapping lightly around the edge of the cap 6 Repeat the procedure for the opposite wheel 7 Install wheels and finger tighten lug nuts 8 Lower the vehicle and finish tightening lug nuts using a crisscross pattern to 55 ft lb 74 6 ...

Page 73: ... affect vehicle handling When selecting a replacement tire use only original equipment or comparable tires WHEELS See General Warnings Section 1 Page 1 1 WHEEL REMOVAL 1 Slightly loosen the lug nuts on the wheel to be removed 2 Raise the end of the vehicle from which the wheel is to be removed Make sure that the wheels are off the ground See General Warnings Section 1 Page 1 1 3 Remove the lug nut...

Page 74: ...m 3 3 When top bead is free of the rim pull the bead from the bottom side of the rim up into the upper part of the rim well Insert the tire tool under the lower bead as shown Figure 8 1 Page 8 2 Detail C and carefully pry the lower bead over the rim flange 3 4 Once the lower bead is started over the rim flange the tire can be removed from the rim by hand TIRE REPAIR 1 Determine the location and ca...

Page 75: ...ater solution to both tire beads and rim flanges 4 Install the tire on the rim from the valve stem side If there is no tire machine available use a rubber mallet and tire iron 5 Remove the valve core and position tire so that both beads are on the rim flange narrow bead seats 6 Place tire and wheel assembly against wall in upright position and push it against wall while inflating tire to 30 35 psi...

Page 76: ... and Service Manual 8 Tire Installation Continued 7 Quickly remove the air nozzle and install the valve core 8 Adjust air pressure in tire to recommended pressure See Section 2 Vehicle Specifications 9 Immerse the wheel and tire assembly in water to make sure there are no leaks ...

Page 77: ...er remove the nut 5 cup washer 9 and rubber bushing 10 from the stem at the top of the shock absorber 3 Remove the nut 5 cup washer 9 and rubber bushing 10 from lower mounting stem 4 Compress the shock absorber to remove it SHOCK ABSORBER INSTALLATION 1 To install reverse the removal procedure 2 On the upper and lower shock absorber mounting stems tighten the nuts until the rubber bushing expands ...

Page 78: ...cedent IQ System Golf Car Maintenance and Service Manual 9 Figure 9 1 Rear Suspension Assembly and Mounting 16 TYPICAL 2 PLACES 9 10 10 9 5 6 8 7 4 3 4 17 1 14 4 2 4 2 11 3 4 12 13 15 17 2 TYPICAL ON EACH SIDE OF VEHICLE BRAKE CABLE HANGER MOUNTING ...

Page 79: ...the tire and wheel assembly on the side from which the spring is to be removed 4 Remove the bow tie locking pin 1 and the clevis pin 2 at the brake lever and brake cable connection and remove cable end 3 from the brake lever Figure 9 3 Page 9 3 Detach the brake cable from the shock mount bracket 4 5 Remove the nut 5 cup washer 9 and rubber bushing 10 from the lower mounting stem of the shock absor...

Page 80: ...springs reverse the removal procedure See following CAUTION CAUTION When positioning the spring on the transaxle be sure to insert the locating bolt on the spring in the locating hole in the transaxle saddle 2 Tighten the nuts on the U bolts to 35 ft lb 46 5 N m 3 Tighten nuts 2 on spring mounting bolts 17 to 18 4 ft lb 25 N m Figure 9 1 Page 9 2 ...

Page 81: ...a guide to inspect the vehicle This checklist should be used daily to ensure that the vehicle is in proper working condition and in conjunction with the Periodic Service Schedule on page 10 2 Any problems should be corrected by a Club Car distributor dealer or a trained technician General All the parts should be in place and properly installed Be sure that all nuts bolts and screws are tight Safet...

Page 82: ...l noises such as squeaks or rattles Check the vehicle s ride and perfor mance Have a Club Car distributor dealer or a trained technician investigate anything unusual Zero Speed Detect With the vehicle parked on level ground and the park brake disengaged place the Tow Run switch in the RUN position and attempt to push the vehicle Motor braking should engage and cause resistance to rolling moving at...

Page 83: ...essary See Section 13 Batteries Monthly service by owner or trained technician Batteries Wash battery tops and clean terminals with baking soda water solution Apply Battery Terminal Protector Spray CCI P N 1014305 to battery terminals Tires Check air pressure and adjust if necessary See Section 2 Vehicle Specifications General vehicle Thoroughly wash vehicle including the underside Semiannual serv...

Page 84: ... owner or trained technician every 50 hours of operation or 100 rounds of golf Charger receptacle WD 40 Brake system per maintenance and service manual Dry Moly Lube CCI P N 1012151 white lithium grease NLGI 2 Front suspension two fittings Chassis Lube EP NLGI Grade 2 Annually by trained technician only every 100 hours of operation or 200 rounds of golf Check fill transaxle to plug level 22 oz 0 6...

Page 85: ...der certain conditions a shunt wound motor also has the ability to act as an electri cal brake to slow the vehicle There are three features of the IQ electrical system which will activate the motor braking function Zero Speed Detect Pedal Down Motor Braking and Pedal Up Motor Braking adjustable with the IQDM P handset Zero Speed Detect This prevents the vehicle from rolling away uncontrolled shoul...

Page 86: ...al as motor overheating could result By reducing the current to the motor during such an occurrence the motor protection circuit reduces the possibility of motor damage When this situation arises a motor stall fault is recorded by the speed controller and will be displayed on an IQDM handset in the Diagnostic History menu See the IQDM Owner s Manual High Pedal Detect This function prevents unexpec...

Page 87: ...t Figure 11 1 Page 11 4 Solid state speed control circuit Figure 11 2 Page 11 6 Tow Run switch circuit Figure 11 3 Page 11 8 ONBOARD COMPUTER CIRCUIT The onboard computer OBC circuit performs the following functions 1 Powers down the electrical system during long term storage to reduce battery discharge 2 Turns the charger on and off during the charge cycle 3 Locks out the motor speed controller t...

Page 88: ... 6 7 9 10 11 16 12 13 14 15 8 RED BLACK RED RED YELLOW LT BLUE BLACK BLACK RED RED WHITE W HITE GREEN BROWN WHITE BROW N W HITE GREEN ORANGE KEY SWITCH BLUE TOW RUN SWITCH BLUE RED RED PINK RED RED SONIC WELD SONIC WELD SIX PIN CONNECTOR BATTERY CONTROLLER SOLENOID BANK DASH LIGHT ONBOARD COMPUTER S1 S2 B M B MOTOR CONTROLLER OUTPUT REGULATOR BLACK GRAY BLACK GREEN RED SONIC WELD GREEN NINE PIN CO...

Page 89: ...es vehicle ground speed by using the MCOR to determine accelerator pedal position 3 Activates the reverse buzzer when the Forward Reverse rocker switch is in REVERSE 4 Regulates direction of vehicle movement through the Forward Reverse switch OBC WIRE FUNCTION Red 18 gauge Main power supply for the onboard computer The vehicle batteries provide 48 volts to the onboard computer White 18 gauge The T...

Page 90: ...CK W HITE BLACK PURPLE YELLOW FORWARD REVERSE SWITCH TOW RUN SWITCH PINK RED BLUE RED SONIC WELD BLACK BATTERY BANK BLUE WHITE ONBOARD COMPUTER YELLOW MOTOR CONTROLLER OUTPUT REGULATOR BLACK 1 2 3 4 RED CONTROLLER A1 F2 A2 F1 GREEN RED RED PIN 1 WHITE BLACK WIRE PIN 16 BLUE WIRE PIN 2 YELLOW WIRE PIN 3 PURPLE WIRE PIN 8 WHITE WIRE PIN 15 RED WIRE PIN 14 LIGHT GREEN WIRE PIN 13 BLACK WHITE WIRE 1 2...

Page 91: ...urple 18 gauge MCOR potentiometer negative Pin 4 Open No wire Pin 5 Light Blue 18 gauge Solenoid lockout circuit the OBC provides a 48 volt signal to the speed controller when the battery charger is disconnected Pin 6 Green 18 gauge MCOR limit switch the limit switch provides 48 volts to the speed controller to turn the speed controller on when the accelerator pedal is pressed Pin 7 Orange White 1...

Page 92: ...E PIN 6 GREEN WIRE PIN 7 ORANGE WHITE WIRE PIN 8 WHITE WIRE PIN 12 BLUE WHITE WIRE 1 2 3 4 5 6 7 9 10 11 16 12 13 14 15 8 RED LIGHT BLUE RED BLUE WHITE YEL LT BLUE BLACK W HITE W HITE GREEN GREEN TAN GREEN TAN WHITE GRAY ORANGE W HITE BROW N W HITE BROW N W HITE GREEN PINK GREEN RED REVERSE BUZZER KEY SWITCH BLUE BLUE TOW RUN SWITCH RED PINK RED LIGHT BLUE BLUE RED BLUE SONIC WELD SONIC WELD BLACK...

Page 93: ...ect motor generated current to the batteries The power circuit consists of Battery pack four 12 volt batteries Solid state speed controller Electric motor Solenoid contacts All 6 gauge power wires Two 10 gauge motor field coil wires Electric Motor The electric motor is explained in detail in another section See Section 15 Motor Figure 11 4 Power Circuit S1 S2 B M B 1 2 3 4 A1 F2 A2 F1 RED BATTERY ...

Page 94: ...ck The charge circuit supplies current from the battery charger to the batteries when the DC cord is plugged into the vehicle s charger receptacle The batteries are explained in detail in another section See Section 13 Batteries Figure 11 5 Charge Circuit S1 S2 B M B 1 2 3 4 BLACK BLACK RED BLACK BATTERY BANK RED BLACK BLACK RED GRAY ONBOARD COMPUTER FRONT OF VEHICLE SINGLE POSITION CONNECTOR CHAR...

Page 95: ... 2 A1 F2 A2 F1 G R E E N R E D BLA CK BLACK WHITE LIGHT GREEN RED YELLOW GREEN W H IT E BL UE O R A N G E RED LIGHT BLUE RED BLUE WHITE YEL LT BLUE W HITE W HITE GREEN GREEN TAN GREEN TAN WHITE GRAY ORANGE W HITE BROW N W HITE BROW N W HITE GREEN PINK GREEN RED TO IQDM PORT REVERSE BUZZER KEY SWITCH BLUE BLUE TOW RUN SWITCH RED PINK PINK RED RED LIGHT BLUE BLUE RED RED RED BLUE SONIC WELD SONIC WE...

Page 96: ...s unavailable the technician should proceed to Troubleshooting Guide 2 TROUBLESHOOTING GUIDE 1 The following troubleshooting guide is intended for use with an IQDM handset For IQDM operating instruc tions refer to the IQDM Owner s Manual See following NOTE NOTE Before troubleshooting the vehicle check the diagnostic history from the Special Diagnostics Menu Note any fault codes TROUBLESHOOTING GUI...

Page 97: ...16 pin connector to the speed controller Failed Forward Reverse rocker switch Test Procedure 15 Forward Reverse Rocker Switch on page 11 40 Test Menu MAIN CONT solenoid does not indicate ON when the solenoid should be activated or Diagnostic Menu MAIN CONT DNC main contactor solenoid did not close fault code Speed controller logic malfunction Disconnect the batteries and allow the speed controller...

Page 98: ...e speed controller See Speed Controller Removal Section 12 Page 12 11 Diagnostic Menu MAIN COIL FAULT fault code or Diagnostic Menu MAIN DROPOUT fault code Solenoid coil has failed in an open condition Replace solenoid See Solenoid Removal Section 12 Page 12 12 Diagnostic Menu FIELD MISSING fault code Loose or disconnected motor field coil wires at motor or speed controller or broken wire Repair a...

Page 99: ...icle Onboard computer failure Test Procedure 2 Onboard Computer Solenoid Lockout Circuit on page 11 19 Key switch and MCOR limit switch circuit Check for loose or disconnected wires at key switch and MCOR Failed key switch Test Procedure 8 Key Switch and MCOR Limit Switch Circuit on page 11 24 Failed MCOR Test Procedure 8 Key Switch and MCOR Limit Switch Circuit on page 11 24 See also Test Procedu...

Page 100: ...Replace speed controller See Speed Controller Removal Section 12 Page 12 11 Brakes improperly adjusted See Section 6 Wheel Brake Assemblies Tires under inflated or flat tires See Section 8 Wheels and Tires Vehicle operates but motor braking function does not Wiring improperly wired Check vehicle wiring See Wiring Diagram on page 11 11 Speed sensor disconnected or failed Test Procedure 13 Motor Spe...

Page 101: ...e cover must be removed to gain access to the various components that are mounted on the component mounting plate Remove screw 1 and remove cover 2 Figure 11 7 Page 11 17 See following WARNING WARNING Shorting of battery terminals can cause personal injury or death Do not place component mounting plate directly on top of batteries when removing or installing plate Remove plate from vehicle complet...

Page 102: ...ECK See General Warnings Section 1 Page 1 1 NOTE The batteries must be properly maintained and fully charged in order to perform the following test procedures Battery maintenance procedures including watering information and allowable min eral content can be found in Section 13 of this manual See Battery Care Section 13 Page 13 4 The battery voltage can be displayed with the IQDM handset If an IQD...

Page 103: ...ading is 48 50 volts proceed to Test Procedure 3 Solenoid Activating Coil on page 11 20 3 Place insulation piercing probe on the light blue 18 gauge wire at a point between OBC six pin connector and main wire harness If reading is 48 50 volts check the wire terminal connectors inside six pin con nector at OBC six pin connector Make sure pins are properly aligned inside housing Make sure wire col o...

Page 104: ...tive post and place the red probe with insulation piercing probe on the red 18 gauge wire harness side of six pin connector Multimeter should indicate 48 volts If voltage is correct check connections in the six pin connector If connections are correct OBC activation circuit has failed Replace OBC TEST PROCEDURE 3 SOLENOID ACTIVATING COIL See General Warnings Section 1 Page 1 1 1 Disconnect the bat...

Page 105: ...r of the vehicle with a chain hoist or floor jack Position jack stands under the frame rails just forward of each spring mount See following WARNING WARNING The key switch should be placed in the OFF position and left in the OFF position for the duration of this test 2 With the batteries connected placeTow Run switch in RUN Using a multimeter set to 200 volts DC place red probe on battery no 1 pos...

Page 106: ...all the way to the floor the multimeter should indicate between 5 67k Ω ohms and 7 43k Ω ohms 8 6 Using a multimeter set for 20k Ω 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 black wire with an insulation piercing probe 8 7 With the accelerator pedal fully up not pressed the multi...

Page 107: ...oceed to step 5 otherwise perform the following procedure Tow Run Switch Test without the IQDM Handset 5 With the IQDM still connected to the vehicle place the Tow Run Switch in the TOW position and wait 90 seconds 6 If the IQDM display screen goes blank after 90 seconds the Tow Run switch and connecting wires are operating correctly 7 If the IQDM display screen is still active after 90 seconds th...

Page 108: ...urate 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 the true condition of the batteries For more information about the batteries refer to Section 13 Batteries TE...

Page 109: ...witch and MCOR Limit Switch Circuit Test without the IQDM Handset 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 2 Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack Position jack stands under the frame rails just forward of each spring mount 3 Turn the key switch to ...

Page 110: ...reen wire where it connects to the MCOR With the Tow Run switch in the RUN position the key switch ON the Forward Reverse rocker switch in NEUTRAL and the accelerator pedal pressed the reading should be approximately 48 volts full battery voltage 5 4 5 If the reading is zero volts test the continuity of the MCOR limit switch and the green wire If the limit switch does not pass the continuity test ...

Page 111: ... 16 pin connector Figure 11 11 Page 11 28 CAUTION Do not fully insert probes into the 16 pin plug Doing so can result in a poor connection 5 With the accelerator pedal fully up not pressed the multimeter should read approximately 1k Ω ohms 6 Slowly press the accelerator pedal while monitoring the multimeter The resistance should rise as the pedal is pressed When the pedal is all the way to the flo...

Page 112: ...pin connector provides a connection point for the solenoid lockout circuit from the onboard computer to the speed controller 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 2 Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack Position jack stands under the frame rails ...

Page 113: ...hen the charger is not connected to the vehicle 13 If any other reading is obtained check the following items Continuity of the wires in the wire harness Onboard computer for proper operation See Test Procedure 11 Onboard Computer Gray Wire on page 11 37 Tow Run switch for proper operation See Test Procedure 6 Tow Run Switch on page 11 23 Test Procedure 9C Pin 6 See General Warnings Section 1 Page...

Page 114: ...zero volts DC at this time 8 While monitoring the multimeter slowly press the accelerator pedal and hold the pedal at approximately 20 of full travel 9 After a short delay the onboard computer should power up come out of sleep mode 10 The multimeter should indicate full battery voltage approximately 48 volts when the accelerator pedal is pressed 11 While observing the multimeter release the accele...

Page 115: ...n connector at the speed controller 4 Place a jumper wire with an alligator clip between the B terminal of the speed controller use alligator clip for this connection and pin 7 orange white wire of the 16 pin connector Figure 11 14 Page 11 31 See following CAUTION CAUTION Do not fully insert probes into the 16 pin plug Doing so can result in a poor connection 5 Place the Tow Run switch in the TOW ...

Page 116: ...ert probes into the 16 pin plug Doing so can result in a poor connection 5 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m 6 Place the Tow Run switch in the RUN position and the Forward Reverse switch in the NEUTRAL position The multimeter should indicate zero volts DC at this time 7 While monitoring t...

Page 117: ...rward of each spring mount 3 Disconnect the 16 pin connector at the speed controller 4 Using a multimeter set for 200 volts DC insert the red probe of the multimeter into pin 9 gray wire of the 16 pin connector See following CAUTION Using an alligator clip connect the black probe to the B terminal of the speed controller Figure 11 16 Page 11 34 CAUTION Do not fully insert probes into the 16 pin pl...

Page 118: ...i tion 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 2 Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack Position jack stands under the frame rails just forward of each spring mount 3 Disconnect the 16 pin connector at the speed controller 4 Using a multimeter set f...

Page 119: ...int for the solenoid coil to the speed controller The speed controller activates the solenoid coil by providing a ground to the solenoid coil at the appropriate time 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 2 Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack Po...

Page 120: ...located inside the onboard computer acts as a switch on the negative side of the circuit This allows the onboard computer OBC to control the battery charging current Use the following procedure to test the SCR 1 With batteries connected and using a multimeter set to 200 volts DC place the red probe on the pos itive post of battery no 1 and place the black probe on the charger receptacle socket tha...

Page 121: ...g the DC cord into the vehicle s charger receptacle The voltage reading should drop to approximately 4 0 volts before the charger relay clicks on 3 When the charger relay is activated the reading should 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...

Page 122: ...et in the three pin connector The voltage reading should be 48 to 50 volts full battery voltage 3 2 If the reading is zero volts check the continuity of the black white wire from the 16 pin connector at the speed controller to the three pin connector at the motor speed sensor If the continuity is cor rect replace the speed controller 4 Check voltage at the red motor speed sensor wire 4 1 With Tow ...

Page 123: ...ft the rear of the vehicle with a chain hoist or floor jack Position jack stands under the frame rails just forward of each spring mount 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 3 Disconnect the three wires that are crimped together from the forward large post of the solenoid 4 Using a multimeter set to 200k ...

Page 124: ...e IQDM should indicate that REVERSE INPUT is ON If the IQDM indicates any other reading check vehicle wiring SeeWiring Diagram on page 11 11 Also check the 16 pin connector at the speed controller See Test Pro cedure 9 16 Pin Connector on page 11 26 5 If the IQDM displays readings other than those described above and the wiring is found to be correct pro ceed to the following procedure Forward Rev...

Page 125: ...orange white wire terminal end that was disconnected from the reverse buzzer and place the red probe on battery no 1 positive post The reading should be approximately 48 volts full battery voltage 7 1 If the voltage reading is correct replace the reverse buzzer 7 2 If reading is zero volts check orange white wire continuity and connection at Pin 7 in 16 Pin con nector 7 3 If there is no continuity...

Page 126: ...6 Install the wedgelock in the six pin connector housing and reconnect the six pin connector plug Place the Tow Run switch in the RUN position and the battery light should illuminate If the light does not illu minate replace the battery warning light assembly COMMUNICATION DISPLAY MODULE CDM The CDM can be used to retrieve from the onboard computer four important items of information that can be u...

Page 127: ...and the first time a set of batteries is charged after the batteries have been disconnected and reconnected A problem may exist if persistent DVDT readings are obtained 4 Indicates the last charge cycle was normal 8 Indicates the charger ran for sixteen hours and shut itself off without completing the charge cycle This means there may be a problem in the charge circuit The CDM also has a low batte...

Page 128: ...played To view F4 press and hold the button on the CDM until Func 4 appears in the display window Release the button The value for F4 will be displayed NOTE The values of all four functions can be recalled by pressing and releasing the CDM button CDM TROUBLESHOOTING GUIDE Use the following chart as a starting point for troubleshooting problems with communication between the CDM and onboard compute...

Page 129: ...n 11 Page 11 24 Key Switch Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Remove the instrument panel Figure 12 1 Page 12 1 2 1 Remove three screws 1 from the instrument panel 2 Figure 12 1 Page 12 1 2 2 Rotate the instrument panel up and away from the dash to disengage the tabs at the top of the panel 2 ...

Page 130: ...2 2 Page 12 2 2 Connect the blue and green wires to the key switch terminals Either orientation is correct See Wiring Diagram Section 11 Page 11 11 3 Install the instrument panel 3 1 Connect the electrical connector 3 Figure 12 1 Page 12 1 3 2 Position the instrument panel 2 on the dash assembly Make sure tabs on upper edge properly engage with the corresponding slots on the dash assembly Ensure t...

Page 131: ...l Warnings Section 1 Page 1 2 2 Remove instrument panel See step 2 of Key Switch Removal on page 12 1 3 Disconnect the wires at the warning light 4 Press the two retaining tabs 11 and remove the light from the center dash Figure 12 3 Page 12 3 Battery Warning Light Installation 1 Install in reverse order of removal 2 Place the Tow Run switch in the TOW position and connect the battery cables posit...

Page 132: ... switch 3 and push switch out of housing Forward Reverse Rocker Switch Installation 1 Route the three wires through bezel Connect the three wires to the rocker switch 3 exactly as shown in Figure 12 4 Page 12 4 2 Orient the rocker switch 3 so the terminals are towards the front of the housing 1 Push rocker switch 3 into housing 1 Figure 12 4 Page 12 4 3 Place the housing in position on the body an...

Page 133: ...d hour meter Electronics Module Cover Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Remove the screw 1 that holds the cover 2 over the electronics module Figure 12 5 Page 12 6 3 Hold battery wire out of way and lift cover 2 off the vehicle Electronics Module Cover Installation 1 Hold battery wire out of ...

Page 134: ...e 12 6 Page 12 7 4 Remove Tow Run switch 2 from bracket 5 Disconnect the two wires 3 and remove switch Tow Run Switch Installation 1 Installation is reverse of removal Make sure flat on switch is aligned with the flat on bracket Tighten Tow Run switch boot hex nut 1 to 16 in lb 1 8 N m Figure 12 6 Page 12 7 2 Install the electronics module cover See Electronics Module Cover Installation on page 12...

Page 135: ...ure 8 Page 11 24 MCOR Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Remove pedal group See Pedal Group Removal Section 5 Page 5 1 3 Disconnect the two pin and three pin connectors 1 from the MCOR 2 Figure 12 7 Page 12 7 4 Remove the hex head screws 3 connecting the MCOR to the pedal group Figure 12 6 Tow...

Page 136: ...on 1 Page 1 1 Testing the Reverse Buzzer See Test Procedure 16 Section 11 Page 11 41 Reverse Buzzer Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Remove instrument panel See step 2 of Key Switch Removal on page 12 1 3 Disconnect the 18 gauge pink and orange white wires from reverse buzzer 4 Remove the tw...

Page 137: ... wires from the screw threads Figure 12 9 Page 12 10 4 Disconnect the 16 pin connector 4 pin connector and the spade connectors from the top of the control ler 5 Remove two nuts on top of the solenoid 2 posts and remove the wires from the posts 6 Disconnect the spade connectors on the front of the solenoid 7 On driver side of the electronic module separate the 6 pin connector and disconnect all le...

Page 138: ...12 Figure 12 9 Electronics Module Removal S 2 S 1 M B B S 2 S 1 4 PIN CONNECTOR TO MOTOR 16 PIN CONNECTOR POWER CONNECTIONS BLACK WIRE TO CONTROLLER OBC FROM DRIVER SIDE GRAY WIRE TO CHARGER RECEPTACLE 6 PIN CONNECTOR YELLOW FROM CONTROLLER SOLENOID ORANGE AND RED TO OBC BLUE ORANGE GREEN YELLOW WHITE BLACK 5 1 3 2 4 ...

Page 139: ...l sound as a warning when the Forward Reverse switch is in REVERSE Make sure that the vehicle does not operate when the Forward Reverse switch is in the NEUTRAL position SOLID STATE SPEED CONTROLLER See General Warnings Section 1 Page 1 1 Testing the Solid State Speed Controller See Test Procedure 5 Section 11 Page 11 22 Speed Controller Removal 1 Disconnect the battery cables as instructed See WA...

Page 140: ...hicle 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 Reverse switch is in REVERSE Make sure that the vehicle does not operate when the Forward Reverse switch is in the NEUTRAL position SOLENOID See General Warnings Section 1 Page 1 1 The solenoid is located on the passenger side of the electri...

Page 141: ...connect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Remove electronics module cover See Electronics Module Cover Removal on page 12 5 3 Disconnect wires Figure 12 9 Page 12 10 4 Loosen but do not remove the two self tapping screws 3 holding OBC to component mounting plate Figure 12 10 Page 12 12 5 Slide OBC upwards to alig...

Page 142: ... mended Charger Receptacle Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Remove electronic module cover 3 Remove kick plate See Kick Plate and Charger Bezel Section 4 Page 4 7 4 Remove the 10 gauge red wire from the positive post of battery no 1 Figure 12 11 Page 12 15 5 Disconnect the black wire from it...

Page 143: ...OMPONENTS Charger Receptacle 2004 Precedent IQ System Golf Car Maintenance and Service Manual Page 12 15 12 Figure 12 11 Charger Receptacle 1 GREY TO OBC TYPICAL 3 PLACES BLACK TO CONNECTOR RED TO BATTERY 1 POST 2 ...

Page 144: ...12 ...

Page 145: ... and maintain an accessory load of 10 25 amperes in stop and go driving The energy removed from an automotive battery is immediately replaced by the alternator or generator As a result the automotive battery operates at 90 to 100 of full charge at all times The batteries supplied with an electric vehicle must supply 100 of the energy required to operate the vehi cle These batteries therefore recei...

Page 146: ...fate PbSO4 immersed in water H2O This will not generate elec tricity because the battery is completely discharged When a discharged battery is connected to a charger the process is reversed The sulfate SO4 is forced from the plates back into the electrolyte to make sulfuric acid H2SO4 The oxygen returns to the positive plate to make lead dioxide PbO2 Figure 13 4 Page 13 2 The result is a charged b...

Page 147: ...arge This vehicle is running slowly but we can run it until it stops Avoid deep discharge of batteries whenever possible See Deep Discharge on page 13 7 Early excessive discharging These are new batteries They can run all day New batteries do not reach their full capacity until they have been used and recharged 20 to 50 times See Early Excessive Discharging on page 13 7 Mineral content Tap water w...

Page 148: ...so tight as to crack or buckle battery case Tighten to 49 5 in lb 5 6 N m alternating between hold down bolts 6 Install wires in proper sequence Figure 13 5 Page 13 4 Install black wire to negative post of battery no 4 last Make sure all connections are tight Tighten to 110 in lb 12 4 N m Coat all terminals with Bat tery Terminal Protector Spray CCI P N 1014305 to minimize future corrosion 7 Give ...

Page 149: ...charge batteries should always be kept clean Hot weather also has an effect on a battery s self discharge rate The higher the temperature the quicker a set of batteries will discharge In hotter climates batteries should be checked more often When storing batteries keep in a cool place See Battery Storage on page 13 14 ELECTROLYTE LEVEL CAUTION Do not allow battery acid from battery caps or hydrome...

Page 150: ...the battery It may also cause acid to leak out of the vent caps and corrosion to build up on surrounding metal parts The acid which is lost reduces the capacity of the battery and cannot be replaced Battery hold downs should NOT be so tight as to crack or buckle the battery case This may cause leaks which would dry out a cell or cause internal short circuits See Battery Replacement on page 13 3 BA...

Page 151: ...mit the use of any vehicle with new batteries for at least the first four weeks and then grad ually increase their range INCOMING AC SERVICE Make sure the incoming AC line service is sufficient If 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 t...

Page 152: ... and within 1 0 V All readings below 14 0 V but within 1 0 V Check electrical system and charger for problems SeeTroubleshooting Guide If problem is not found go to on charge voltage test Any reading below 14 0 volts and not within 1 0 volts of those batteries above 14 0 volts replace battery Replace any battery with a variation of more than 50 points of specific gravity between cells or has a cel...

Page 153: ...3 5 Page 13 4 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 14 0 volts and are within 1 0 ...

Page 154: ...C 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 004 to the reading For each 10 F 5 6 C below 80 F 26 7 C subtract 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 020 or more the low cell should ...

Page 155: ...ive post of battery no 4 Figure 13 9 Page 13 11 VEHICLE NO BATTERY NO ELECTROLYTE TEMPERATURE CORRECTION FACTOR CORRECTED SPECIFIC GRAVITY REQUIRED ACTION CELL 1 CELL 2 CELL 3 CELL 4 CELL 5 CELL 6 12 1 20 F 6 6 C 0 024 1 275 0 024 1 251 1 280 0 024 1 256 1 280 0 024 1 256 1 275 0 024 1 251 1 280 0 024 1 256 1 280 0 024 1 256 Sound Battery Fully Charged 54 3 50 F 10 C 0 012 1 260 0 012 1 248 1 200 ...

Page 156: ... discharge times are low less than 60 minutes replace batteries below 10 05 volts 3 In general battery sets that discharge in less than 60 minutes at 78 F 25 6 C on the discharge test will typically not hold a charge for an entire work shift However discharge time is dependent on the elec trolyte temperature The table shown gives the discharge times at various temperatures of a set of bat teries t...

Page 157: ...e test which lasted 45 minutes battery no 1 is clearly shown to be the problem Battery no 4 should be watched a little more closely but appears to be okay Battery no 1 should be replaced with a bat tery that has about the same age and usage as the other batteries in the set Example 2 Vehicle no 70 was also suspected of having a bad battery due to its performance The battery charger test showed 7 0...

Page 158: ...t are in vehicles for winter storage should be left disconnected in the vehicles if the batteries are not going to be connected to a charger 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 ...

Page 159: ...2004 Precedent Electric Golf Car Maintenance and Service Manual Page 14 1 14 SECTION 14 BATTERY CHARGER Refer to the appropriate battery charger maintenance and service manual ...

Page 160: ...14 ...

Page 161: ... disconnecting TEST PROCEDURE 1 INTERNAL SHORT CIRCUITS See General Warnings Section 1 Page 1 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 2 Using two wrenches to prevent posts from turning disconnect wires from terminals on motor 3 Using a multimeter set to 200 Ω ohms place black probe on motor housing Scratch...

Page 162: ...pen armature windings may be the cause The motor will need to be removed from the vehicle and repaired by a qualified technician See Motor Removal on page 15 3 TEST PROCEDURE 3 FIELD CIRCUIT OPEN See General Warnings Section 1 Page 1 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 2 Using two wrenches to prevent p...

Page 163: ...hicle to let the jack stands support the vehicle Figure 15 3 Page 15 3 See following WARNING WARNING Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 lb 454 kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock ...

Page 164: ...or Disassembly 1 Before beginning disassembly place match marks on the motor end shield and stator shell then place the motor in a vice with wooden blocks as shown Figure 15 5 Page 15 5 2 Remove the four bolts 8 securing the end shield 10 to the stator shell 2 3 Remove the two screws 9 attaching the end shield to the bearing retainer 4 Lift stator shell 2 off of armature 17 5 Remove two screws 11 ...

Page 165: ...ble the motor and carefully inspect the armature for the following characteristics 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 Figure 15 5 Motor Disassembly Figure 15 6 Brush Spring Removal F 2 A...

Page 166: ...l on the commutator may indicate a faulty transaxle input shaft oil seal Armature Ground Test CAUTION Do not submerge the armature in solvent NOTE Before testing the armature wipe it clean with a clean cloth Remove any carbon dust and metal particles from between the commutator bars 1 With a multimeter set to 200 Ω ohms place one probe on the commutator and the other on the armature core The multi...

Page 167: ...ushes 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 15 10 When replacing brushes replace all four brushes Never replace only two Install the brushes in the same rigging 180 apart from each other BEARING INSPECTION 1 Using a clean cloth wipe the carbon dust off of the b...

Page 168: ...e 15 8 2004 Precedent IQ System Golf Car Maintenance and Service Manual 15 Figure 15 10 Motor 16 15 18 4 6 5 3 F 1 A 1 F 2 A 2 22 29 9 TYPICAL 2 PLACES TYPICAL 2 PLACES 11 10 24 21 7 8 TYPICAL 4 PLACES 28 27 2 1 25 26 TYPICAL 3 PLACES 14 13 17 12 30 ...

Page 169: ...re the bearing retainer 16 is positioned on the armature shaft before the bearing is pressed onto the armature Figure 15 10 Page 15 8 An arbor with an outside diameter of less than 5 8 inch 16 mm should be used to press the bear ing onto the armature 2 Install the speed sensor magnet See Speed Sensor Magnet Installation on page 15 9 SPEED SENSOR MAGNET INSPECTION Inspect the speed sensor magnet 18...

Page 170: ... stator shell insert the two terminal posts through insulators in stator shell wall at the A1 and A2 positions Insert brush holder screws through the holes in the brush rigging and into the threaded holes in the mounting bracket Figure 15 12 Page 15 12 Tighten the screws to 20 in lb 2 3 N m 2 2 One at a time push brush spring extensions back from brushes and slide the brushes back until they are c...

Page 171: ...6 by aligning the two holes in the bearing retainer with the two mating holes in the end shield and installing the screws 9 Figure 15 10 Page 15 8 Tighten the screws to 17 in lb 1 9 N m See following NOTE NOTE Use a long screw with the same thread specifications as the mounting screws to maintain hole alignment while starting the first mounting screw Figure 15 13 Page 15 12 3 2 Align the match mar...

Page 172: ...moly teflon lubricant CCI P N 102265201 from tube onto a putty knife as shown Figure 15 14 Page 15 13 2 2 Rotate wheels to rotate input shaft 2 3 Apply motor coupling grease evenly to the rotating input shaft starting at approximately 1 8 inch 3 1 mm from the end of the shaft and working back toward the transaxle away from the end of the shaft Figure 15 15 Page 15 13 2 4 The grease should be evenl...

Page 173: ...g 4 Install motor on transaxle 4 1 Slide the motor coupling onto the transaxle input shaft See following NOTE NOTE The coupling will push any excess grease on the input shaft along the shaft toward the transaxle When the motor is pushed onto the input shaft the motor adapter ring 1 will not bottom out against the transaxle housing Figure 15 10 Page 15 8 There will be approximately 1 16 inch 1 6 mm...

Page 174: ... operation 4 10 Connect the three pin speed sensor wire to the vehicle wire harness 5 If using a chain hoist lower the vehicle and guide the leaf springs into the shackles If using a floor jack raise the transaxle until the leaf springs can be guided into the shackles 6 Insert the mounting bolts through the spring shackles and the bushings in the leaf spring eyes and install lock nuts Tighten the ...

Page 175: ...ng a screwdriver gently pry the motor speed sensor 21 from recessed area on the motor end shield Motor Speed Sensor Installation 1 Position the motor speed sensor 21 as shown and firmly press the speed sensor into the motor end shield Sensor should fit flush against the motor Figure 15 20 Page 15 16 2 Connect the three pin connector 22 to the vehicle wire harness 3 Place the Tow Run switch in the ...

Page 176: ...MOTOR Motor Speed Sensor Page 15 16 2004 Precedent IQ System Golf Car Maintenance and Service Manual 15 Motor Speed Sensor Installation Continued Figure 15 20 IQ Motor Speed Sensor 21 22 ...

Page 177: ...RICATION See General Warnings Section 1 Page 1 1 There are two plugs located on the lower half of the transaxle housing The upper plug 21 as viewed when the vehicle is on a level surface is used as a lubricant level indicator Figure 16a 5 Page 16a 3 When the vehicle is parked on a level surface the lubricant level should be even with the bottom of the hole The lower plug 22 is for draining the lub...

Page 178: ...1016417 to remove the axle seal and adapter ring from the axle tube Figure 16a 2 Page 16a 2 See following CAUTION and NOTE CAUTION Do not scar or damage the inside surfaces of the tube when removing the oil seal and adapter ring A damaged tube might have to be replaced NOTE Do not discard the adapter ring If the adapter ring is lost or damaged the axle tube will have to be replaced 6 2 Use a press...

Page 179: ... System Golf Car Maintenance and Service Manual Page 16a 3 16A Figure 16a 5 Transaxle Type G REFERENCE MOTOR SECTION 15 1 3 14 15 39 24 26 34 13 33 36 32 8 9 10 11 12 20 18 19 16 16 16 17 23 21 25 36 22 35 13 27 30 31 29 2 3 8 9 36 27 30 28 37 38 5 6 4 15 39 ...

Page 180: ... See following NOTE NOTE There is a LEFT and RIGHT side axle The splined portions on the axles that insert into the trans axle case are two different lengths The longest length spline is the LEFT or driver side axle 2 1 Insert the splined end of the axle shaft into the axle tube Be careful not to damage the seal on the inside of the axle tube hub Advance the shaft through to the bearing on the sha...

Page 181: ...d of the spring mount Lower the vehicle to let the jack stands support the vehicle Figure 16a 6 Page 16a 5 4 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 5 Remove the bow tie pins 1 and brake cable clevis pins 3 Use tool CCI P N 102555501 to compress tangs on cable end and remove cable end from bracket 3 Figure 16a 7 Page 16...

Page 182: ...he motor 10 Remove the three motor mounting bolts Figure 16a 11 Page 16a 6 and the motor positioning bolt Figure 16a 12 Page 16a 7 mounting the motor to the transaxle See following WARNING WARNING Do not position fingers under motor when sliding motor off of the input shaft Fingers may get pinched when motor disengages Figure 16a 8 Disconnect Shocks Figure 16a 9 Shackles Figure 16a 10 Leaf Springs...

Page 183: ...16a 1 See following NOTE NOTE Recycle or dispose of used oil or lubricant in accordance with local state and federal regulations 16 Remove the brake assemblies if required See Brake Cluster Removal Section 6 Page 6 9 TRANSAXLE DISASSEMBLY INSPECTION AND ASSEMBLY See General Warnings Section 1 Page 1 1 TRANSAXLE DISASSEMBLY AND INSPECTION 1 To detach axle tubes 14 and 35 from the transaxle housing ...

Page 184: ...mbly press off together the bearing 16 and the gear 19 Figure 16a 5 Page 16a 3 See also Figure 16a 13 Page 16a 8 7 Press the bearing 18 off the intermediate gear assembly Figure 16a 5 Page 16a 3 8 Disassemble the differential gear case 8 1 Remove four hex bolts 33 that secure the ring gear to the differential case Figure 16a 5 Page 16a 3 8 2 Remove the ring gear Retain dowel pin 34 from between th...

Page 185: ...l gears and thrust plates 3 and 4 8 7 Inspect the bearings 13 of the differential case 26 and replace them if they are damaged Figure 16a 5 Page 16a 3 To remove them press them off See following CAUTION CAUTION Do not reuse bearings after removing them Replace bearings with new ones 9 Inspect parts for wear or damage Any worn or damaged parts should be replaced See following NOTE NOTE Damaged or w...

Page 186: ...h 3 mm bead of Three Bond liquid gasket on mating surface of housing 8 2 Install left half of transaxle housing 20 Figure 16a 5 Page 16a 3 8 3 Install eleven bolts 24 in the case housing and tighten to 19 ft lb 25 7 N m Type G transaxles have no shims or gasket 8 4 Install axle tube 14 and 35 with lock washers and bolts 9 and 8 Figure 16a 5 Page 16a 3 Tighten the bolts to 36 ft lb 49 N m 9 Install...

Page 187: ...he pilot bolt in the leaf spring assembly 3 Install the two U bolts jounce bumper mount and spacers lock washers and nuts Tighten the nuts to 25 ft lb 34 N m Tighten the U bolt nuts so an equal amount of thread is visible on each leg of the bolt 4 Install the motor See Motor Installation Section 15 Page 15 12 5 If using a chain hoist lower the vehicle while guiding the leaf springs into the rear s...

Page 188: ... 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 Reverse switch is in REVERSE Make sure that the vehicle does not operate when the Forward Reverse switch is in the NEUTRAL position ...

Page 189: ...ATION See General Warnings Section 1 Page 1 1 There are two plugs located on the lower half of the transaxle housing The upper plug 25 as viewed when the vehicle is on a level surface is used as a lubricant level indicator Figure 16b 4 Page 16b 3 When the vehicle is parked on a level surface the lubricant level should be even with the bottom of the hole The lower plug 44 is for draining the lubric...

Page 190: ...d bearing assembly by pulling the axle straight out of the housing 6 Use a 16 inch 40 cm rolling wedge bar Figure 16b 2 Page 16b 2 to remove oil seal Insert the wedge bar underneath the seal lip and pry out oil seal 17 Figure 16b 3 Page 16b 2 See following CAU TION CAUTION Do not scar or damage the inside surfaces of the tube when removing the oil seal A damaged tube might have to be replaced 7 In...

Page 191: ...lf Car Maintenance and Service Manual Page 16b 3 16B Figure 16b 4 Transaxle Type K 7 4 6 5 37 31 30 29 28 27 41 26 6 5 17 4 7 2 3 20 21 23 18 18 4 16 7 17 5 6 25 44 22 38 14 REFERENCE MOTOR SECTION 15 39 8 9 32 36 34 35 34 33 14 37 40 1 3 8 9 12 11 10 42 43 13 24 18 19 ...

Page 192: ...n be removed Axle Bearing Installation 1 If removed place retaining ring 6 on axle shaft 1 or 2 Figure 16b 4 Page 16b 3 The retaining ring will be loose on the axle shaft until it is installed into the axle tube 2 Apply two drops of Loctite 271 to the inside of the collar CAUTION Apply Loctite 271 to inside of collar only not to the shaft so the Loctite will be pushed away from the bearing as the ...

Page 193: ...e transaxle See following NOTE NOTE There is a LEFT and RIGHT side axle The splined portions on the axles that insert into the trans axle case are two different lengths The longest length spline is the LEFT or driver side axle 3 1 Insert the splined end of the axle shaft into the axle tube Be careful not to damage the seal on the inside of the axle tube hub Advance the shaft through to the bearing...

Page 194: ...555501 to compress tangs on cable and remove cable from bracket 3 Figure 16b 8 Page 16b 6 6 Disconnect the shock absorbers from their lower mounts Figure 16b 9 Page 16b 7 7 Disconnect the four motor wires Use two wrenches to prevent the post from turning 8 With a floor jack supporting the transaxle remove lower spring shackle nuts and bolts Position shackles so they are clear of springs Figure 16b...

Page 195: ...le to the leaf springs Figure 16b 11 Page 16b 7 14 Carefully lift each end of the transaxle off its positioning pin on the leaf spring and slide the transaxle to the rear and out of the vehicle 15 Drain the lubricant from the transaxle and remove the axle shafts See Axle Shaft and Oil Seal Removal on page 16b 1 See following NOTE NOTE Recycle or dispose of used oil or lubricant in accordance with ...

Page 196: ...ves of the housing 11 and 24 apart If necessary tap lightly on the spline of the input pinion 19 See following CAUTION CAUTION To prevent damage to the housing mating seal surfaces use caution when separating halves 4 Remove input pinion gear 19 by pulling gear out while rocking intermediate gear assembly 23 Lift intermediate gear assembly and differential gear case unit out simultaneously Figure ...

Page 197: ...the ring gear 30 Figure 16b 4 Page 16b 3 See also Figure 16b 16 Page 16b 9 9 2 Remove eight hex bolts 28 that secure the ring gear to the differential case Figure 16b 4 Page 16b 3 9 3 Remove the ring gear Retain dowel pin 41 from between the ring gear and differential case for reassembly 9 4 Separate the differential gear case housing If necessary install two of the hex bolts removed pre viously i...

Page 198: ...d parts should be replaced See following NOTE NOTE Damaged or worn gears should be replaced as sets TRANSAXLE ASSEMBLY CAUTION Do not press against the bearing outer race Gasket 13 faces of the housing must be clean and smooth use only a new gasket that is not torn or damaged The gasket must lie flat against the housing faces Figure 16b 4 Page 16b 3 The housing and all parts must be wiped clean an...

Page 199: ...ng 24 Figure 16b 4 Page 16b 3 8 3 Install the ten bolts 26 and tighten to 69 in lb 7 8 N m 8 4 If the axle tube 16 and 40 was removed install the shims 39 if the shims were removed and Three Bond liquid gasket Install the axle tube with five lock washers and bolts 9 and 8 Tighten the bolts to 36 ft lb 49 N m NOTE If the differential case 33 and 36 the transaxle housing 11 and 24 or axle tube 16 an...

Page 200: ...l indicator hole with 22 ounces of SAE 30 API Class SE SF or SG oil a higher grade may also be used Install and tighten the level indicator plug 25 to 23 ft lb 31 N m SHIMMING THE TRANSAXLE If the differential case 36 and 33 transaxle housing 11 and 24 or axle tube 16 and 40 has been replaced the transaxle may need new shims To determine whether new shims are necessary the transaxle must be comple...

Page 201: ...osts from turning See following NOTE NOTE If the motor wires were not tagged when disconnected refer to the wiring diagram for proper con nection See Wiring Diagram Section 11 Page 11 11 7 Insert bolts through the spring shackles and bushings in the leaf spring eyes Secure bolts with lock nuts Tighten to 15 ft lb 20 3 N m 8 Connect the brake cables using new bow tie pins 1 Figure 16b 8 Page 16b 6 ...

Page 202: ...16B ...

Page 203: ...harger 16 hour shut off 13 7 AC service incoming 13 7 charge circuit 11 10 numbering vehicles and chargers 13 7 testing 13 9 on charge voltage test 13 9 battery warning light 11 5 installation 12 3 removal 12 3 testing 11 42 bearing axle see transaxle type g axle bearing see transaxle type k axle bearing bearing motor see motor bearing body front 4 3 4 8 see also repair front and rear body install...

Page 204: ... switch installation 12 4 removal 12 4 testing 11 40 front body see body front front bumper and clamshell 4 5 fuse sense lead 11 37 H high pedal detect 11 2 I inspection front wheel free play 7 17 motor armature ground test 15 6 armature inspection 15 5 bearing 15 7 field windings 15 6 motor components 15 7 speed sensor magnet 15 9 pre operation and daily safety checklist 10 1 shock absorber 9 1 t...

Page 205: ...rom 11 43 testing 11 19 11 36 11 37 P panel 4 9 pawl assembly 5 4 Pedal Group 5 1 5 2 5 5 pedal group 5 1 installation 5 6 removal 5 1 Pedal Group Access 5 1 periodic lubrication schedule 10 4 periodic service schedule 10 2 R rack and pinion 7 4 assembly 7 8 disassembly 7 5 7 7 installation 7 9 removal 7 4 rear beauty panel installation 4 11 removal 4 11 rear body see body rear rear suspension see...

Page 206: ...tment 7 11 wheel alignment 7 10 suspension rear leaf spring installation 9 4 removal 9 1 shock absorber inspection and removal 9 1 installation 9 1 T test procedures 1 batteries voltage check 11 18 2 onboard computer solenoid lockout circuit 11 19 3 solenoid activating coil 11 20 3 solenoid diode 11 20 4 MCOR 11 21 5 motor A1 and A2 voltage 11 22 6 Tow Run switch 11 23 7 battery pack voltage under...

Page 207: ...b 1 inspection 16b 8 installation 16b 13 lubrication 16b 1 oil seal installation 16b 5 removal 16b 1 removal 16b 6 shimming 16b 12 troubleshooting 11 11 battery troubleshooting examples 13 13 communication display module CDM 11 44 troubleshooting guide 1 11 12 troubleshooting guide 2 11 15 U universal accessory mounting 4 8 W WARNING definition of 1 1 warning light battery see battery warning ligh...

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

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