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BATTERIES

Battery Replacement

Page 14-18

2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement

14

11. Install wires in proper sequence 

(Figure 14-8, Page 14-18), (Figure 14-9, Page 14-18) 

and

(Figure 14-10, Page 14-18)

. Install black wire to negative post of battery no. 6 last or no. 4 last depend-

ing on battery configuration. Tighten all connections to 110 in-lb (12.4 N·m). Coat all terminals with Bat-
tery Terminal Protector Spray (CC P/N 1014305) to minimize future corrosion.

12. Give the batteries a full charge prior to operation. This ensures all the batteries are fully charged and the

cells are equalized prior to use.

Figure 14-8   Battery Cable Removal – DS Villager

6x8-Volt Battery Configuration

Figure 14-9   Battery Cable Removal – DS Villager

4x12-Volt Battery Configuration

(Viewed from driver side of vehicle)
1. Place TOW/RUN Switch in TOW before disconnecting or 
connecting battery cables.
2. Remove negative battery cable.
3. Remove positive battery cable.
Connect battery cables in reverse order.

(Viewed from driver side of vehicle)
1. Place TOW/RUN Switch in TOW before disconnecting or 
connecting battery cables.
2. Remove negative battery cable.
3. Remove positive battery cable.
Connect battery cables in reverse order.

Figure 14-10   Battery Cable Removal – Turf 1/Carryall 

1 6x8-Volt Battery Configuration

(Viewed from driver side of vehicle)
1. Place TOW/RUN Switch in TOW before disconnecting or 
connecting battery cables.
2. Remove negative battery cable.
3. Remove positive battery cable.
Connect battery cables in reverse order.

1

2

3

5

6

4

(–)

(+)

TOW

RUN

WA

RNIN

G

1

2

3

1

2

3

4

3

2

1

(–)

(+)

3

2

(+)

(–)

1

2

3

4

6

5

1

Содержание Carryall 1

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

Страница 2: ......

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

Страница 4: ...rove its vehicles and other products These improvements may affect servicing procedures Any modification and or significant change in specifications or proce dures will be forwarded to all Club Car di...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 41: ...11 28 CAUTION Do not fully insert probes into the 16 pin plug Doing so can result in a poor connection 5 Place the Tow Run switch in the TOW position and connect the battery cables positive cable fir...

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

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

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

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

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

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

Страница 48: ...3 Disconnect the 16 pin connector at the speed controller 4 Place a jumper wire with an alligator clip between the B terminal of the speed controller use alligator clip for this connection and pin 12...

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

Страница 50: ...in connector The voltage reading should be 48 to 50 volts full battery voltage 3 2 If the reading is zero volts check the continuity of the black white wire from the 16 pin connector at the speed cont...

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

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

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

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

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

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

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

Страница 58: ...11...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 99: ...causes the plates to shed prematurely and shortens the life of the battery It may also cause acid to leak out of the vent caps and corrosion to build up on surrounding metal parts The acid which is l...

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

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

Страница 102: ...9 3V and within 0 7V All readings below 9 3V but within 0 7V Check electrical system and charger for problems SeeTroubleshooting Guide If problem is not found go to on charge voltage test Any reading...

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

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

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

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

Страница 107: ...Battery no 1 should be replaced with a bat tery that has about the same age and usage as the other batteries in the set Example 2 Vehicle no 70 was also suspected of having a bad battery due to its pe...

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

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

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

Страница 111: ...times are low less than 60 minutes replace batteries below 10 05 volts 3 In general battery sets that discharge in less than 60 minutes at 78 F 25 6 C on the discharge test will typically not hold a...

Страница 112: ...ut appears to be okay Battery no 1 should be replaced with a bat tery that has about the same age and usage as the other batteries in the set Example 2 Vehicle no 70 was also suspected of having a bad...

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

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

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

Страница 116: ...14...

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

Страница 118: ...15...

Страница 119: ...OTOR TESTING The following tests can be performed without disassembling the motor using a multimeter or continuity tester NOTE Tag the motor wires for identification before disconnecting TEST PROCEDUR...

Страница 120: ...2 terminal The multimeter should indicate continuity If the reading is incorrect a possible open field coil or bad connections at the terminals may be the cause The motor will need to be removed from...

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

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

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

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

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

Страница 126: ...ystem Electric Vehicle Maintenance and Service Supplement 16A Figure 16a 9 Motor Model 5BC59JBS6390 16 15 18 4 6 5 3 F 1 A 1 F 2 A 2 22 29 9 TYPICAL 2 PLACES TYPICAL 2 PLACES 11 10 24 21 7 8 TYPICAL 4...

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

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

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

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

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

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

Страница 133: ...re 16a 19 Page 16a 15 3 Using a screwdriver gently pry the motor speed sensor 21 from recessed area on the motor end shield Motor Speed Sensor Installation 1 Position the motor speed sensor 21 as show...

Страница 134: ...16A...

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

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

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

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

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

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

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

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

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

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

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

Страница 146: ...at a time This method ensures the terminals and brushes will be properly positioned in the rigging When replacing brushes replace all four brushes Never replace only two Install the brushes in the sam...

Страница 147: ...o support the weight of the commutator The brushes can be easily damaged by this weight 4 Gently press each brush with a small screwdriver until the spring rests on the end of each brush as shown Figu...

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

Страница 149: ...Make sure the motor is properly seated in the transaxle housing NOTE Failure to install and tighten the motor mounting bolts in the proper sequence and to the proper tightness may result in motor noi...

Страница 150: ...en lug nuts using a crisscross pat tern to 55 ft lb 74 6 N m 10 Place the Tow Run switch in the TOW position and connect the batteries positive cable first Tighten battery terminals to 110 in lb 12 4...

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

Страница 152: ...r ring 39 Figure 17 3 Page 17 2 Retain the adapter ring and discard the oil seal 7 Inspect the axle shaft assembly to be sure the bearing and collar have not slipped and are still seated against the s...

Страница 153: ...Q System Electric Vehicle Maintenance and Service Supplement Page 17 3 17 Figure 17 5 Transaxle Type G 1 3 14 15 39 24 26 13 33 36 32 8 10 11 12 20 18 19 16 16 16 17 23 21 25 36 22 35 13 27 30 31 29 2...

Страница 154: ...to damage the seal on the inside of the axle tube hub Advance the shaft through to the bearing on the shaft then rotate it to align the shaft splines with the splined bore of the differential side ge...

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

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

Страница 157: ...Remove input pinion gear 17 by pulling gear out while rocking intermediate gear assembly 19 Lift intermediate gear assembly and differential gear case unit out simultaneously Figure 17 5 Page 17 3 Se...

Страница 158: ...2 Remove the ring gear 8 3 Separate the differential gear case housing If necessary install two of the hex bolts removed pre viously in step 8 1 into the differential gear unit and while holding the...

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

Страница 160: ...lines with the splined bore of the differential gear Continue advancing the shaft until the bearing on the axle is firmly seated within the axle tube hub seat 11 2 Using 90 internal snap ring pliers 0...

Страница 161: ...r con nection See Wiring Diagrams Section 11 Page 11 2 7 Insert bolts through the spring shackles and bushings in the leaf spring eyes Secure bolts with locknuts Tighten to 15 ft lb 20 3 N m 8 Connect...

Страница 162: ...17...

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

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

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

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

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

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

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

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