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05 Electric Service Manual

1. Figure 10 1 Vehicle Lubrication Points 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 10 3 SECTION 11 ELECTRICAL SYSTEM AND TESTING A DANGER e See General Warnings Section 1 Page 1 1 A WARNING e See General Warnings Section 1 Page 1 1 e 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 completely GENERAL INFORMATION The IQ System vehicle uses a 48 volt electrical system that is powered by four 12 volt lead acid batteries and includes an onboard computer The IQ System vehicle uses a shunt wound 3 2 hp motor and includes several additional features e Shunt Wound Motor The shunt wound motor unlike a series motor is designed so that the speed controller is able to vary the amount of current passing through the field coils independently from the current passing through the armature Motor Braking Under 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 I QDM P handset Zero Speed Detect T
2. Figure 15a 8 Brush Spring Tension Test Figure 15a 9 Inspect Bearing 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15a 7 15A 15A MOTOR MODEL 5BC59JBS6365 Motor Component Testing and Inspection Figure 15a 10 Motor Page 15a 8 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual 15A MOTOR MODEL 5BC59JBS6365 Reconditioning the Motor BEARING REMOVAL 1 Place the wedge attachment tool CCI P N 1012812 between the bearing 15 and the armature 17 Figure 15a 10 Page 15a 8 Make sure the wedge attachment tool is supporting the inner race of the bearing If a press is not available secure a bearing puller CCI 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 removed Figure 15a 11 Page 15a 11 Discard the bearing and speed sensor magnet See following NOTE NOTE The speed sensor magnet will be pressed off by the bearing when the bearing is removed BEARING INSTALLATION 1 Press a new bearing 15 onto the armature Figure 15a 10 Page 15a 8 Use an arbor press that exerts pressure on the inner race only See following NOTE NOTE Make sure the bearing retainer 16 is positioned on the armature shaft before the bearing is pressed onto the armature Figure 15a 10 Page 15a 8 An arbor with an outside diameter of less than 5 8 inch 16 mm
3. Figure 6 4 Self adjusting Wheel Brake Assembly Page 6 3 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual 6 WHEEL BRAKE ASSEMBLIES Brake Shoe Removal Brake Shoe Removal Continued 9 Using needle nose pliers turn the clip retainer pin 1 90 to remove the shoe retainer clip 2 Figure 6 5 Page 6 4 A CAUTION e 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 Figure 6 5 Remove Shoe Retainer Clip Figure 6 6 Remove Brake Shoes 11 Remove adjuster wheel 1 with two washers 2 and 3 from the backing plate Figure 6 7 Page 6 4 easel Figure 6 7 Remove Adjuster Wheel Figure 6 8 Lubricate Slide and Slide Plate Page 6 4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning el BRAKE ASSEMBLY CLEANING See General Warnings Section 1 Page 1 1 See also Warning on Page 6 1 1 Carefully clean the brake backing plate and all of its mechanical components 2 Remove the rubber boot from backing plate and wipe with a clean damp cloth 3 Lubricate the slide 1 and slide plate 2 with dry moly lubricant CCI P N 1012151 on both sides of the backing plate Figure 6 8 Page 6 4 After lubricating work the slide back and forth to ensure that
4. MCOR Voltage Test without the IQDM Handset 1 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 See WARNING Lift only one end in General Warnings Section 1 Page 1 2 See also following WARNING A WARNING e 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 positive post and place black probe with insulation piercing probe on the purple wire at a point close to the three pin connector at the MCOR The reading should be approximately 48 50 volts full battery voltage 3 If reading is zero volts check the purple wire continuity from the three pin connector at the MCOR to the 16 pin connector at 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 cor rectly replace the speed controller 4 With multimeter set to 20 volts DC place the black probe on battery no 4 negative post and the red probe with insulation piercing probe on the white black wire at a point close to the three pin con nector at the MCOR The reading should be approximately 4 65 volts 5
5. cable first Tighten battery terminals to 110 in Ib 12 4 N m and coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion Place the Tow Run switch in the RUN position Inspect the vehicle for proper operation See following WARNING A WARNING e Make sure that the vehicle operates in the forward direction when the Forward Reverse switch is in the FORWARD position e 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 e Make sure that the vehicle does not operate when the Forward Reverse switch is in the NEUTRAL position Page 15a 14 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual MOTOR MODEL 5BC59JBS6365 Motor Speed Sensor VIEWED FROM DRIVER Figure 15a 18 Motor Installation Figure 15a 19 Motor Mount MOTOR SPEED SENSOR See General Warnings Section 1 Page 1 1 Testing the Motor Speed Sensor See Test Procedure 13 Section 11 Page 11 34 Motor Speed Sensor Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Disconnect the three pin connector 22 from the vehicle wire harness Figure 15a 20 Page 15a 16 3 Using a screwdriver gently pry the motor speed sensor 21 from recessed ar
6. 15a 10 15b 11 Speed Sensor eeeeceeeeeeeeseeeeseeetereeeeeeeeeeeee 15a 15 installation aissi nearne 15a 15 le UCNE 15a 15 E DEE 11 34 speed sensor magnet INSPOCTION veisins 15a 9 15b 9 UC UE ls E 15a 9 ul CET 15a 9 TeStINg tege ee i es 11 18 see test procedures motor Zero speed detect ceceeseeeeeeeeeeteeeeeeeeeeeees 11 1 motor braking see regenerative braking motor controller output regulator MCOR installation ee 12 7 Cu VUE 12 7 testing NEE 11 17 11 20 O onboard computer OBC aaeeseeeeeeeeea 11 7 Installation 2 9tedE e we AA ee E Ed 12 13 FEDOOTIAG WE 11 37 ue VUE 12 13 retrieving data from eese 11 39 testing ciartai a 11 15 11 32 11 33 P pawl assembly AA 5 4 pedal group Ipsiallaton r araa eaae meas aeaeaie oiie e 5 6 Eu VE 5 1 periodic lubrication schedule An 10 3 periodic service schedule AAA 10 1 R rack AN PINION ereere 7 4 Eu EE 7 8 disassembly iieri esa e eaa 7 5 7 7 Installation ed EE ye alee 7 9 POMMOVAll EER E E E 7 4 rear beauty panel INStAN ALON cenen annn 4 12 4 16 KETATON Ae EAA A AA 4 10 4 15 rear body see body rear rear body four passenger ee 4 12 rear body two passenger eeen 4 8 rear suspension see suspension rear rear underbody installation cccccccccceseceeseeseseeeeeeeeeeeeaes 4 12 4 16 DEEN esbetugue E E A a 4 12 4 16 receptacle see charger receptacle regenerative braking AAA 11 7 repair front and rear body gouges
7. Ifa chain hoist was used to raise the vehicle lift the vehicle high enough to permit easy access and clear ance for removal of the motor If a floor jack was used to raise the vehicle lower the transaxle enough to permit easy access and clearance for removal of the motor Remove the three motor mounting bolts Figure 16 11 Page 16 6 and the motor positioning bolt Figure 16 12 Page 16 7 mounting the motor to the transaxle See following CAUTION A CAUTION 12 13 14 15 e Do not position fingers under motor when sliding motor off of the input shaft Fingers may get pinched when motor disengages MOTOR MOUNTING PINION GEAR INTERMEDIATE DIFFERENTIAL GEAR ASSEMBLY GEAR CASE Figure 16 10 Leaf Springs Figure 16 11 Motor Mounting Bolts Carefully remove the motor from the transaxle Slide the motor away from the transaxle until the motor spline becomes disengaged from the input shaft then lift motor out See preceding WARNING If a floor jack was used pull floor jack from beneath the transaxle and allow the springs to rest on the floor Remove the U bolts attaching the transaxle to the leaf springs Figure 16 10 Page 16 6 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 Drain the lubricant from the transaxle and remove the axle shafts See Axle Shaft and Oil Seal Removal on page 16 1 See following
8. Replace the speed controller See Speed Controller Removal Section 12 Page 12 11 Diagnostic Menu HPD high pedal detect fault code Operator error Train operators to fully remove foot from accelerator pedal before turning key switch to the ON position or changing the selected direction with the Forward Reverse switch Diagnostic Menu LOW BATTERY fault code Batteries require charging Place batteries on battery charger and allow them to fully charge Improperly maintained or failed batteries Section 13 Batteries Diagnostic Menu MOTOR STALL fault code Operator error Train operators to use the brake to hold the vehicle on a hill rather than holding the vehicle on a hill using the accelerator pedal Diagnostic Menu OPEN ARMATURE fault code Loose or disconnected motor armature wires at motor or speed controller or broken wire Repair and or connect the motor armature wires Failure of the motor armature or brushes Section 15a Motor Model 5BC59JBS6365 Failure of the FET s that control armature current Replace the speed controller See Speed Controller Removal Section 12 Page 12 11 Page 11 10 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL SYSTEM AND TESTING TROUBLESHOOTING GUIDE 2 Troubleshooting TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Ve
9. 2 Tighten the nuts on the U bolts to 25 ft lb 84 N m 3 Tighten nuts 2 on spring mounting bolts 17 to 15 ft lb 20 3 N m Figure 9 1 Page 9 2 LEAF SPRINGS FOUR PASSENGER VEHICLES See General Warnings Section 1 Page 1 1 LEAF SPRING REMOVAL FOUR PASSENGER VEHICLES 1 Loosen but do not remove lug nuts on tire and wheel assembly on the side from which the spring is to be removed Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack Position jack stands under the frame crossmember forward of the spring mounting tabs Lower the vehi cle to let the jack stands support the vehicle Figure 9 2 Page 9 3 See following WARNING A WARNING e Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 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 the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes Place a floor jack under the transaxle differential casing to support but not lift the drivetrain Raise it just enough to relieve tension on the shock absorbers without compressing them Remove the tire and wheel assembly on the side from which the spring is to be removed Remove the bow tie loc
10. 4 3 Check continuity on A1 and A2 motor terminal posts and continuity of the F1 and F2 motor terminal posts Also check continuity of all motor wires See Section 15a Motor Model 5BC59JBS6365 TEST PROCEDURE 6 TOW RUN SWITCH See General Warnings Section 1 Page 1 1 Tow Run Switch Test with the IQDM Handset 1 With the Tow Run switch in the RUN position connect the IQDM to the vehicle as described in the QDM Owner s Manual 2 Immediately after the IQDM is connected to the vehicle the screen should display a copyright notice and the IQDM model number 3 Ifthe IQDM display screen is blank drive the vehicle a short distance to activate the onboard computer 4 If the IQDM display screen begins to work after the vehicle has been driven turn the key switch to the OFF position and proceed 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 Ifthe IQDM display screen is still active after 90 seconds the switch has failed closed Replace the Tow Run switch See Tow Run Switch Removal Section 12 Page 12 6 Tow Run Switch Test without the IQDM Handset 1 With the batteries connected and using a multimeter set on 200 volts DC connect
11. Axle Shaft and Oil Seal Removal Continued 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 to separate the axle oil seal 15 from the adapter ring 89 Figure 16 3 Page 16 2 Retain the adapter ring and discard the oil seal 7 Inspect the axle shaft assembly to be sure the bearing and collar have not slipped and are still seated against the shoulder on the axle shaft 8 Inspect bearing 5 Figure 16 5 Page 16 3 If the bearing in a Type G transaxle is worn or damaged the entire axle shaft assembly 1 or 2 must be replaced Figure 16 1 Axle Tube Figure 16 2 Axle Seal and Adapter Ring Removal ADAPTER a RING LIP Figure 16 3 Axle Seal and Adapter Ring Figure 16 4 Axle Seal and Adapter Ring Installation Page 16 2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual TRANSAXLE TYPE G Axle Bearing and Shaft Figure 16 5 Transaxle Type G 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 16 3 TRANSAXLE TYPE G Axle Bearing and Shaft Axle Shaft and Oil Seal Installation 1 If previously removed install a new oil seal 1 1 Clean seal seat in the adapter ring 39 Figure 16 3 Page 16 2 1 2 Place a new seal 15 in the adapter ring with the seal lip facing toward the adapter ring lip Figure 16 3 Page 16 2 Use an axle seal tool CCI P N
12. BATTERIES Battery Storage BATTERY STORAGE See General Warnings Section 1 Page 1 1 When storing batteries during the off season or when maintaining a replacement stock follow these guidelines 1 Keep the batteries clean and free of corrosion See Battery Care on page 13 2 2 Batteries that 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 stored at 80 F 26 7 C will have to be recharged every few weeks 5 48 volt Club Car electric vehicles and compatible battery chargers are designed to be left connected with AC power to the charger ON during off season storage The storage charge feature will automati cally charge the batteries as needed throughout the storage period CHARGING A BATTERY PACK THAT HAS LOW VOLTAGE See the appropriate battery charger maintenance and service manual Page 13 12 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual SECTION 14 BATTERY CHARGER Refer to the appropriate battery charger maintenance and service manual 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 14 1 15A
13. Figure 4 8 Page 4 11 Remove canopy supports Remove four screws 13 attaching the rear beauty panel 12 to the fuel bucket Remove two screws 14 and remove Forward Reverse switch housing 15 from vehicle Disconnect electrical wires from the Forward Reverse switch 16 DP GOT st 23 Lift rear beauty panel from vehicle Page 4 10 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual BODY AND TRIM Rear Body Two Passenger Vehicles TWO PASSENGER VEHICLES ONLY cr TYPICAL 4 PLACES iy iN SS Lay TWO PASSENGER VEHICLES ONLY TWO PASSENGER VEHICLES ONLY Figure 4 8 Rear Body Components 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 4 11 BODY AND TRIM Rear Body Four Passenger Vehicles Rear Beauty Panel Installation 1 Install rear beauty panel 12 on vehicle Make sure body clips on the rear of the beauty panel engage the mating slot in the rear underbody Secure beauty panel in place with four screws 13 Tighten screws to 3 7 ft lb 5 N m Figure 4 8 Page 4 11 2 Connect the three wires to the Forward Reverse switch 16 as shown 3 Position the Forward Reverse switch 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
14. Page 4 12 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual BODY AND TRIM Rear Body Four Passenger Vehicles Seat Back Installation Secure seat back 8 or 11 to seat support with screws 9 or 13 Tighten screws to 71 in lb 8 N m Figure 4 11 Page 4 15 SEAT SUPPORT Seat Support Removal 1 Remove screws 8 and 11 securing the rear hip restraints 6 and remove the hip restraints from the vehicle Figure 4 9 Page 4 13 2 Remove the screws 5 and bolts 4 from the seat support 3 and remove the seat support from the vehi cle Seat Support Installation 1 Install in the reverse order of removal 2 Tighten bolts 4 to 53 in lb 6 N m Tighten screws 5 to 44 in lb 5 N m Tighten bolts 8 and 11 to 124 in lb 14 N m Figure 4 9 Page 4 13 TYPICAL 10 2 PLACES TYPICAL 8 4 PLACES f al ge TYPICAL 2 PLACES TYPICAL N 4PLACES si Figure 4 9 Seat Supports Four Passenger Vehicles 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 4 13 BODY AND TRIM Rear Body Four Passenger Vehicles TYPICAL 10 PLACES 6 PLACES 4 PLACES Figure 4 10 Foot Deck Four Passenger Vehicles FOOT DECK Foot Deck Removal 3 Remove screws 8 and 11 securing the rear hip restraints 6 and remove the hip restraints from the veh
15. 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 9 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 align heads of self tapping screws 3 with the two key holes in the OBC face plate and remove OBC Onboard Computer Installation 1 Install the OBC onto the component mounting plate by aligning the two holes on the OBC face plate with two holes on component mounting plate Slide OBC down and align heads of self tapping screws 3 with smaller part of two holes in OBC face plate Figure 12 10 Page 12 12 Tighten screws to 5 5 ft lb 7 5 N m 2 Connect wires Figure 12 9 Page 12 9 Make sure all connections are fully seated and boot on gray sense lead is properly seated 3 Install electronics module cover See Electronics Module Cover Installation on page 12 5 4 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m and coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion CHARGER RECEPTACLE See General Warnings Section 1 Page 1 1 The charger cord plug and receptacle are wear items and should be inspected daily Visually inspect them for cracks loose connectio
16. 1 to 53 in lb 6 N m BRAKE RETURN SPRING A CAUTION e Spring is under tension Use caution when working with springs The brake return spring 5 provides the pressure needed to return the brake pedal to its upright position Figure 5 4 Page 5 5 One end of the spring attaches to a hook on pedal 11 and the other end attaches to pedal base 12 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 5 3 a ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group PAWL ASSEMBLY The pawl assembly 6 serves to lock the brakes when the PARK pedal is pressed The pawl assembly also releases the brakes when either the STOP or GO pedal is pressed Figure 5 4 Page 5 5 The pawl assem bly is serviced as a unit The replacement unit includes two snap rings 7 pin 8 spring 9 and pawl unit 6 When replacing the unit ensure spring 9 is properly positioned to be held in place when the pin 8 is installed Secure the pin with two snap rings 7 ACCELERATOR RETURN SPRING The accelerator return spring assembly 10 consists of two springs and three T shaped bars secured 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 A CAUTION e Spring is under tension Use caution when working with springs 1 With the pedal group removed from the v
17. 18 ORANGE E 16 ORANGE 16 BLACK 14 BLACK d 18 BLUE WHITE 16 YELLOWWHITE 12 BLACK 16 PURPLE 16 BLACK WHITE 12 BLACK 16 ORANGE 14 YELLOW CONNECTS TO MAIN HARNESS SEE FIGURES 11 1 AND 11 2 16 BROWN 16 GREEN 14 YELLOW 16 RED 16 BLUE WHITE Gel S LIGHT SWITCH 16 WHITE 16 WHITE 16 BLACKWHITE 16 BROWN 6 YELLOW 12 BLUE 12 BLACK 16 BROWNWHITE 16 YELLOW 16 GREENWHITE 16 BROWN WHITE 18 GREEN 16 GRN WHT 18 BLUE WHITE 18 BLUE WHITE 888088888800 SON WELD i 18 ORANGE 18 ORANGE K SONIC WELD 18 BLUE WHITE 18 BROWN Ny d g BLUE WHITE DIODE L SONIC WELD 18 BLUE WHT BRAKE LIGHT RELAY NOTE SOME WIRING COMPONENTS SHOWN ARE OPTIONAL ACCESSORIES Figure 11 4 Precedent Electric Vehicle Accessory Wiring Diagram 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11 5 ELECTRICAL SYSTEM AND TESTING KEY SWITCH 1 ff SONIC WELD Wiring Diagrams OPTIONAL BATTERY INDICATOR m m 9 PIN CONNECTOR CONNECTS TO MAIN HARNESS SEE FIGURES 11 1 AND 11 2 18 RED 18 BROWN WH
18. 2 over the electronics module 2 Install screw 1 to secure cover in place Tighten screw to 3 4 ft lb 4 6 N m CAUTION e Exposure to water many damage electronic components Do not operate vehicle without this cover properly installed Do not direct water stream in the area of the cover 3 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m and coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion Son i ELECTRONICS TOW RUN Ge MODULE UI ill Il Ulli Figure 12 5 Electronics Module Cover 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 12 5 ELECTRICAL COMPONENTS Electronics Module Cover TOW RUN SWITCH See General Warnings Section 1 Page 1 1 Testing the Tow Run Switch See Test Procedure 6 Section 11 Page 11 19 Tow Run Switch Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 Remove the electronics module cover See Electronics Module Cover Removal on page 12 5 Remove Tow Run switch boot hex nut 1 Figure 12 6 Page 12 6 Remove Tow Run switch 2 from bracket Disconnect the two wires 3 and remove switch Tow Run Switch Installation 1 Installation is reverse of removal Make sure flat o
19. SAM Removal 1 If the vehicle has a canopy the rear upright supports must be removed from the SAM 1 Remove four bolts 4 to release the SAM 3 from the vehicle Figure 4 7 Page 4 9 SAM Installation 1 Position the SAM 8 over its mounting holes and secure with four screws 4 Tighten screws to 53 in lb 6 N m Figure 4 7 Page 4 9 Backrest The backrest 1 is secured to the SAM 3 with two screws 2 Figure 4 7 Page 4 9 When replacing 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 7 Page 4 9 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 12 to 4 8 ft lb 6 5 N m and screws 10 to 11 8 ft lb 16 N m Figure 4 7 Page 4 9 Sweater Basket The sweater basket 11 is secured to the bag hoop assembly by three screws 12 Tabs on the upper edge of the basket align with holes in the bag hoop 6 for installation purposes Tighten screws 12 to 4 8 ft lb 6 5 N m to secure the sweater basket Figure 4 7 Page 4 9 REAR BODY COMPONENTS TWO PASSENGER Rear Beauty Panel Removal 1 Remove SAM See SAM Removal on page 4 10 2 Remove one screw 3 from each canopy support bracket 1 and 2
20. SECTION 15A MOTOR MODEL 5BC59JBS6365 Ei A DANGER e See General Warnings Section 1 Page 1 1 A WARNING e See General Warnings Section 1 Page 1 1 GENERAL INFORMATION The IQ System vehicle is equipped with a 48 volt DC shunt wound reversible traction motor The shunt wound motor is designed for use on the IQ System vehicle only Club Car recommends that motors requiring major repair be sent to a qualified motor repair shop however there are many relatively simple tasks that can be performed by a technician with general knowledge and experience in electric motor repair MOTOR IDENTIFICATION There are two types of motors used in 2005 model year IQ System electric vehicles Model 5BC59JBS6365 gray housing and EJ4 4001 black housing Do not attempt to service a motor that has not been properly identified If the motor cannot be properly identified contact your local Club Car dealer or distributor EXTERNAL MOTOR TESTING Using a multimeter or continuity tester the following tests can be performed without disassembling the motor NOTE Tag the motor wires for identification before 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 terminal
21. Then position the brush springs against the sides of the brushes so that spring pressure will hold them in the retracted position Figure 15a 6 Page 15a 5 Page 15a 10 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual MOTOR MODEL 5BC59JBS6365 Motor Assembly BEARING PULLER CCI P N 1012811 2 3 a ANS Figure 15a 11 Bearing Removal Slide the armature bearing end first into the stator shell Make sure the brushes are held back while positioning the armature for proper commutator brush contact Release the brushes and place the springs outside the brushes so the brushes are being held against the commutator See following CAUTION CAUTION e If the motor is being assembled with the armature standing on end as the commutator is positioned make sure the brushes are held back Do not allow the brushes to support the weight of the stator shell The brushes can be easily damaged by this weight 3 Install the end shield onto the stator shell 3 1 NOTE 3 2 NOTE Attach the end shield 10 to bearing retainer 16 by aligning the two holes in the bearing retainer with the two mating holes in the end shield and installing the screws 9 Figure 15a 10 Page 15a 8 Tighten the screws to 17 in lb 1 9 N m See following 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
22. Trim RACK AND PINION See General Warnings Section 1 Page 1 1 RACK AND PINION REMOVAL aR on H Remove the front bumper as instructed See Section 4 Body and Trim Remove the retaining pins 1 and tie rod end retaining nuts 2 Figure 7 4 Page 7 5 Remove the tie rod ends 3 from the spindle assemblies Remove the three bolts 5 from the steering rack and pinion assembly mounting bracket Remove the bolt 6 from the universal joint then remove the rack and pinion assembly and universal joint from the vehicle Page 7 4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual STEERING AND FRONT SUSPENSION Rack and Pinion Figure 7 4 Rack and Pinion Removal RACK AND PINION DISASSEMBLY 1 Remove the two tie rod ends 12 and inspect for excessive wear Figure 7 5 Page 7 6 2 Remove clamps 10 and 21 from bellows 9 Figure 7 5 Page 7 6 NOTE Ifthe dust seal bellows are secured with a metal clamp remove the clamp Do not reuse the clamp when the rack 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 Remove th
23. 012 0 012 Bad no 2 Cell 1 248 1 188 1 258 1 253 1 258 1 248 IDE 1 200 1 180 1 170 1 200 1 180 1 198 EE 38 2 37 8 008 0 008 0 008 0 008 0 008 0 008 0 008 Dette SC 1 208 1 188 1 178 1 208 1 188 1 198 Eiere ae 1 240 1 245 Float 1 235 1 250 1 240 E 22 i 26 7 C 000 0 9 dies 0 Q 0 Replace Batter 1 240 1 245 notrise 1 235 1 250 1 240 H y DISCHARGE TEST If the previous tests have failed to identify the problem conduct a discharge test The discharge test comes closest to simulating actual vehicle operating conditions by continuously drawing current from the batteries until voltage drops to 42 0 volts The discharge test is the hardest test on the batteries and the most time consuming to perform Use the bat tery discharge tester CCI P N 101831901 Performing the Discharge Test 1 Be sure the batteries are fully charged and that the electrolyte level is correct in all cells 2 Connect the tester leads to the positive post of battery no 1 and negative post of battery no 4 Figure 13 5 Page 13 9 FRONT OF VEHICLE RED PROBE TO BATTERY NO 1 BLACK PROBE TO BATTERY NO 4 Figure 13 5 Battery Discharge Test 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 13 9 BATTERIES Battery Testing Performing the Discharge Test Continued 3
24. 1 oil seal INStallAtiony NET 16 2 removals ee a ee 16 1 Felge eege ater tine tes 16 5 troubleshooting AAA 11 2 battery troubleshooting examples 4 13 11 communication display module CDM 11 40 troubleshooting guide 1 11 8 troubleshooting guide 2 11 11 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual U universal accessory Mounting ee 4 8 W WARNING definition Of 14 1 1 water level see batteries electrolyte level wheel installation ce 8 1 FEMOVAl et ie ciate es ek Lee O 8 1 see also tire wheel liner instalation RE 4 12 RETANO e E EEEE F EEA Measesbeagine 4 12 wheel steering see steering wheel Z Zero speed detect AAA 11 1 Page i 5 Your Comments Are Appreciated Please select gur cadegory Distributor Dealer C Technician Individual Owner Golf Course Superintendent Club Car Associate Representative Other In order to help us better serve you please rate this publication in the following catgories Poor Fair Average Good Excellent 1 Ease of Understanding 2 Ease of Finding Information 3 Clarity of Illustrations 4 Index Usability 5 Troubleshooting Chart Usability Comments Suggestions Please fax a copy of this page to 706 228 2662 Than
25. 1 1 After disconnecting the batteries wait 90 seconds for the controller capacitors to discharge Do not leave children unattended on vehicle OF VEHICLE Place TOW RUN Switch in the TOW position before disconnecting or connecting battery cables Figure 1 1 Battery Disconnection Page 1 2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual SECTION 2 VEHICLE SPECIFICATIONS Two Four SPECIFICATIONS Boars Elsana Vehicle Vehicle POWER SOURCE Drive motor Direct drive 48 volts DC shunt wound 3 2 hp e Transaxle Double reduction helical gear with 12 3 1 direct drive axle Electrical system 48 volts DC reduced speed reverse Batteries High capacity deep cycle 12 volt Charger Automatic 48 volt UL and CSA listed Engine 4 cycle OHV 286 cc 9 0 hp rated single cylinder air cooled with pressure lubrication system Fuel system Side draft carburetor with float bowl fixed jets fuel filters and impulse fuel pump Governor Automatic ground speed sensing internally geared in unitized transaxle Ignition Transistor electronic ignition with electronic RPM limiter Unitized transaxle Fully synchronized forward and reverse with neutral and reduced speed reverse 11 8 1 for ward 17 1 1 reverse Torque converter Automatic variable speed dry type El
26. 1014162 and mallet to tap it in until it seats firmly in position Figure 16 3 Page 16 2 A hydraulic press may also be used with the axle seal tool 1 3 Clean adapter ring seat s in the axle tube 14 or 35 Figure 16 5 Page 16 3 1 4 Apply Loctite 603 to the outer diameter of the adapter ring 1 5 Place the oil seal and adapter ring assembly into the axle tube with the seal lip facing away from the bearing Figure 16 4 Page 16 2 Use an axle seal tool CCI P N 1014162 and mallet to tap it in until it seats firmly in position See following CAUTION CAUTION e Clean any residual oil from the exposed end of the axle shaft and from the oil seal area prior to installing the axle shaft to prevent oil from coming in contact with brakes 2 Install the rear axle into the transaxle See following NOTE 2 1 2 2 NOTE 2 3 Insert the shaft splined end first through the seal and 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 then rotate it to align the shaft splines with the splined bore of the differential side gear 27 Figure 16 5 Page 16 3 Continue advancing the shaft until the bearing on the axle is firmly seated within the axle tube hub seat Use a pair of snap ring pliers to install the retaining ring 6 inside axle tube hub so that it seats against the axle bearing assembly and into the machined slot in the inside
27. 17 5 Apply grease to the lip of the new oil seal 10 and install the seal using a transaxle pinion seal tool CCI P N 1014161 The lip of the oil seal should face the inside of the transaxle housing Make sure the seal is firmly seated 6 Install the differential assembly the intermediate gear assembly and the input pinion gear simulta neously Be sure all bearings are seated properly in the housing Rotate the input shaft to check for smooth gear operation Figure 16 11 Page 16 6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 16 9 TRANSAXLE TYPE G Transaxle Installation Transaxle Assembly Continued 7 Install both dowel pins 25 in the transaxle housing 20 Figure 16 5 Page 16 3 8 Install left half of transaxle housing 8 1 Place a 1 8 inch 3 mm bead of Three Bond liquid gasket on mating surface of housing 8 2 Install left half of transaxle housing 20 Figure 16 5 Page 16 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 bolts 8 Figure 16 5 Page 16 3 Tighten the bolts to 37 ft lb 50 2 N m 9 Install the brake assemblies as instructed See Brake Cluster Installation Section 6 Page 6 10 10 Apply a small amount of grease to the lip of the oil seal 15 Figure 16 5 Page 16 3 See following CAUTION A CAUTION e Clean any residual oil
28. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15a 3 15A MOTOR MODEL 5BC59JBS6365 External Motor Testing Motor Removal Continued 8 To gain easier access to the motor lower the transaxle as 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 15a 4 Page 15a 4 See following WARNING A WARNING e Hot Do not attempt to service hot motor this could result in severe burns e Do not position fingers under motor when sliding motor off of the input shaft in step 10 Fingers may get pinched when motor disengages Figure 15a 4 Lower Axle 9 Remove the four bolts that mount the motor to the transaxle Figure 15a 19 Page 15a 15 10 Carefully slide the motor away from the transaxle until the motor spline disengages the input shaft and remove the motor from the vehicle Motor 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 15a 5 Page 15a 5 Remove the four bolts 8 securing the end shield 10 to the stator shell 2 Remove the two screws 9 attaching the end shield to the bearing retainer Lift stator shell 2 off of armature 17 Remove two screws 11 attaching brush rigging 12 to the stator shell 2 Figure 15a 10 Page 15a 8 D mr wo DV Mark the brush termin
29. 24 inserted through the tab to 155in lb 17 5 Nem Figure 15a 18 Page 15a 15 4 8 Install the motor wires making sure they are connected to the correct motor terminals and that the terminal orientation is correct See Wiring Diagrams Section 11 Page 11 2 Using two wrenches to prevent the posts from turning tighten the terminal retaining nuts to 65 in lb 7 3 N m 4 9 Secure the white orange green and blue wires with a wire tie so that none of the motor wires will scrub the motor or transaxle when the vehicle is in operation 4 10 Connect the three pin speed sensor wire to the vehicle wire harness 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 Insert the mounting bolts through the spring shackles and the bushings in the leaf spring eyes and install lock nuts Tighten the bolts to 23 ft lb 31 N m See Section 9 Rear Suspension in the appropriate maintenance and service manual 7 Install the shock absorbers Tighten nut until rubber bushing expands to the diameter of the cup washer 8 If removed install wheels and finger tighten the lug nuts 9 Lift vehicle and remove jack stands Lower vehicle to the floor and tighten lug nuts using a crisscross pat 10 11 12 tern to 55 ft lb 74 6 N m Place the Tow Run switch in the TOW position and connect the batteries positive
30. 53 in lb 6 N m Access Panel Access panel 6 is secured to the rear underbody 4 with two expanding screws 7 Figure 4 8 Page 4 11 When replacing the panel tighten screws 7 enough to hold the panel in place Rear Underbody Removal 1 Remove four screws 5 attaching the rear underbody 4 to vehicle Figure 4 8 Page 4 11 2 Remove two screws 18 and washers 23 that attach the underbody to the two liners 8 and 9 3 Lift the rear edge of the rear underbody 4 until the front portion slides out from beneath the front under body Remove the rear underbody from the vehicle Rear Underbody Installation 1 Install rear underbody 4 on the vehicle Figure 4 8 Page 4 11 Install two washers 23 and screws 18 to secure the underbody to the two wheel liners 8 and 9 and install four screws 5 to secure the underbody to the vehicle Tighten screws 5 and 18 to 3 7 ft lb 5 N m Wheel Liner Removal 1 Remove bolts 10 to release liners 8 and 9 from vehicle Figure 4 8 Page 4 11 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 lb 6 N m REAR BODY FOUR PASSENGER VEHICLES See General Warnings Section 1 Page 1 1 SEAT BACKS Seat Back Removal Remove screws 9 or 13 securing seat back 8 or 11 to seat support and remove the seat back Figure 4 11 Page 4 15
31. 6 Install wires in proper sequence Figure 13 1 Page 13 2 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 the batteries a full charge prior to operation This ensures all the batteries are fully charged and the cells are equalized prior to use BATTERY CARE See General Warnings Section 1 Page 1 1 PREVENTIVE MAINTENANCE To keep batteries in sound operating condition follow these steps on a regular basis 1 Any corrosion build up on or around batteries should be removed immediately Terminal connections should be clean and tight Any frayed or worn wires should be replaced After all cables have been connected coat all terminals with Battery Terminal Protector Spray CCI P N 1014305 to help prevent future corrosion Page 13 2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual BATTERIES Battery Care 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 1 gallon 3 8 L of water Rinse solution off bat teries Do not allow this solution to enter the batteries Be sure terminals are tight Let the terminals dry and then coat them with Battery Terminal Protector Spray CCI P N 1014305 See Self Discharge on pag
32. Check and record the electrolyte temperature of the battery packs Check cell no 2 second cell from positive post in each battery 4 Reset discharge machine and turn the tester ON 5 When the batteries have been discharging for approximately 60 minutes set the discharge machine to function 3 and check battery set voltage Check voltage every 10 minutes throughout the rest of the test As soon as the battery set voltage reaches 0 5 volts above the shut off point 42 0 volts use a multim eter to measure individual battery voltages Measure and record the voltage of each battery to the near est 0 01 volt NOTE The tester will shut off automatically when shut off voltage is reached Interpreting Discharge Test Results 1 If discharge time is 60 minutes or higher the problem is not with the batteries 2 If discharge times are low less than 60 minutes replace batteries below 10 05 volts BATTERY VOLTAGES BATTERY CONDITION 1 2 3 4 10 50V 10 50V 10 50V 10 50 V Excellent 10 60V 10 60V 10 83 V 9 75 V Battery no 4 is near end of useful life 10 8 V 10 8 V 10 01 V 9 41 V Battery nos 3 and 4 are near end of useful life 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 d
33. 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 3 Disconnect the electrical connector 3 to the instrument panel Figure 12 1 Instrument Panel Removal 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 12 1 ELECTRICAL COMPONENTS Key Switch Key Switch Removal Continued 3 Disconnect the wires from the key switch 4 From the back of the instrument panel push down on the retaining tabs surrounding the key switch 4 and remove the key switch cap 8 Hold the key switch and remove the switch retaining nut 6 from the outside of the instrument panel Figure 12 2 Page 12 2 Figure 12 2 Key Switch Key Switch Installation 1 Position the key switch and flat washer 9 in the instrument panel then install and tighten the switch retaining nut 6 to 40 in Ib 4 5 N m Install key switch cap 8 in center dash Figure 12 2 Page 12 2 2 Connect the blue and green wires to the key switch terminals Either orientation is correct See Wiring Diagrams Section 11 Page 11 2 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
34. If reading is zero volts check the white black wire continuity from the three pin connector at the MCOR to the 16 pin connector at 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 the speed controller 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11 17 ELECTRICAL SYSTEM AND TESTING Test Procedures MCOR Voltage Test without the IQDM Handset Continued 6 With multimeter set to 20 volts DC place the black probe on battery no 4 negative post and the red probe with insulation piercing probe on the no 18 yellow wire at a point close to three pin connector at the MCOR The reading should be approximately 0 32 volts with the pedal up Slowly press the accel erator pedal and note the readings on the multimeter As the pedal is pressed the reading should increase until it reaches 4 65 volts when the pedal is fully pressed 7 lf reading does not increase as the pedal is pressed replace the MCOR 8 If the reading is not approximately 4 60 volts with the pedal fully pressed the vehicle will not operate at rated top speed Check the MCOR resistance 8 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally start ing in General Warnings Section 1 Page 1 1 8 2 Disconnect the 16 pin connector at the speed controll
35. See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 Disconnect the 16 pin connector from the speed controller Inspect terminal ends inside plug to ensure they are in position and seated in plug housing If any terminals look like they are not pushed all the way into the connector gently push the terminals until they are firmly seated in the 16 pin connector After each terminal has been pushed into the housing gently pull on the wire to ensure it is locked into place Check wires in the plug to make sure none are broken at the terminal pin crimp Repair or replace as required Check the wire colors of each wire and make sure that the colors for each pin position match the wire colors in the wiring diagram See Wiring Diagrams on page 11 2 When connecting the 16 pin connector to the controller push plug into controller receptacle with enough force to lock plug into place An audible click will be heard when plug is properly seated to the controller A procedure is provided for testing each of the wires in the 16 pin connector Refer to the following chart for the appropriate procedure for each pin in the 16 pin connector Page 11 22 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL SYSTEM AND TESTING Test Procedures If the results of any of the referenced procedures are different from those described in the procedure check the continuity of the wires in th
36. Test Menu KEY INPUT does not indicate ON when key switch is in the ON position Loose or disconnected wires at key switch terminals or broken wire Repair and or connect the quick disconnect terminals to the Forward Reverse switch Loose or disconnected 16 pin connector at speed controller or broken wire Repair and or connect the 16 pin connector to the speed controller Failed key switch Test Procedure 8 Key Switch and MCOR Limit Switch Circuit on page 11 20 Diagnostic Menu THROTTLE FAULT 1 fault code Loose or disconnected three pin connector at the MCOR or broken wire Repair and or connect the three pin connector to the MCOR Loose or disconnected 16 pin connector at speed controller or broken wire Repair and or connect the 16 pin connector to the speed controller Failed MCOR Test Procedure 4 MCOR Voltage on page 11 17 Diagnostic Menu HW FAILSAFE Hardware Failsafe fault code Armature drive FET s field effect transistors inside speed controller have failed Replace the speed controller See Speed Controller Removal Section 12 Page 12 11 Speed controller logic malfunction Disconnect the batteries and allow the speed controller capacitors to discharge See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 Reconnect the batteries and see if the symptom returns Diagnostic Menu MAIN WELDED main solenoi
37. Warnings Section 1 Page 1 1 STEERING WHEEL REMOVAL 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 If scorecard holder is secured to steering wheel with screws remove the two mounting screws 8 Figure 7 3 Page 7 3 3 Remove the scorecard holder plate 1 4 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 5 Loosen the steering wheel bolt 6 and back it off approximately 1 4 inch 6 mm Do not remove the bolt 6 If it is difficult to remove the steering wheel use the steering wheel puller CCI P N 102061201 to remove steering wheel 6 1 Place the puller anvil 4 through the top opening of the steering wheel Figure 7 1 Page 7 2 6 2 Insert the anvil feet through the two slots in the base plate marked B 5 as shown Figure 7 1 Page 7 2 6 3 Rotate the anvil screw 6 clockwise until the base plate contacts the bottom of the steering wheel where it attaches to the steering column Figure 7 2 Page 7 2 6 4 Using a 1 2 inch drive air impact wrench tighten the anvil screw 6 until the steering wheel breaks free from the steering shaft 6 5 Remove the steering wheel puller 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 7 1 STEERING AND F
38. 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 ors match and are connected to the correct terminals 4 If reading is zero volts plug the charger DC cord into the vehicle charger receptacle If the dash light illu minates for 10 seconds the OBC is now powered up Unplug the DC cord the reading at the OBC light blue wire should be approximately 48 50 volts If the vehicle now operates normally the DC cord has powered up the electrical system The electrical system should also power up when the accelerator pedal is pressed To check the accelerator pedal function see Test Procedure 4 MCOR Voltage on page 11 17 5 If the dash light illuminates for 10 seconds and the vehicle does not operate 5 1 Using a multimeter set to 200 volts DC place black probe on battery number 4 and place red probe with insulation piercing probe on light blue 18 gauge wire at OBC six pin connector 5 2 With Tow Run switch in the RUN position the voltage reading should be approximately 48 volts 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11 15 ELECTRICAL SYSTEM AND TESTING Test Procedures Test Procedure 2 Onboard Computer Solenoid Lockout Circuit Continued 6 If the dash light does not illuminate and the v
39. and 13 over the front supports The covers are marked DRIVER and PASS to identify them as going on the driver side or passenger side respectively Do not install the screws 14 yet Insert the two rear canopy supports 3 into the openings on the top of the Structural Accessory Module SAM From the inside of the basket insert two bolts 6 through the basket wall and into each support The bolts are color coded with blue thread lock Finger tighten the bolts to avoid cross threading the threads in the supports See following CAUTION CAUTION e Using tools to thread the bolts could prevent proper feel of the bolt as it captures the female threads in the support This could result in damage to the components Position the canopy on top of the front and rear supports Ensure that the front supports are properly positioned between the molded tabs on the underside of the canopy and that the molded protrusions at the rear of the canopy extend into the top of the rear supports Secure the canopy to the front supports with four bolts 8 and lock nuts 9 Use two bolts on each sup port inserting the bolts from the inside Tighten the lock nuts to 50 in lb 5 6 N m Secure the canopy to the rear supports with two bolts 4 and locknuts 5 Tighten the lock nuts to 50 in Ib 5 6 N m At the rear supports 3 tighten the four bolts 6 to 31 in lb 3 5 N m At the front supports 7 and 10 tighten the four bolts 11 to 18 4 ft
40. axle shaft clean any residual oil from the exposed end of the axle tube and from the oil seal area 2 Be sure bolts 11 CCI P N 1014153 and new lock nuts 10 CCI P N 1013924 are used to mount the brake assembly Figure 6 4 Page 6 3 3 Tighten bolts to 30 ft lb 40 6 N m 4 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 tran saxle case are two different lengths The longest length spline is the LEFT or driver side axle 4 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 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 tip CCI P N 1012560 attach the internal retaining ring into the axle tube hub so that it seats against the axle bearing assembly and into the machined slot in the inside wall of the axle tube hub 4 3 Place a 1 4 to 3 8 inch 6 10 mm diameter rod against the retaining ring and tap lightly at four or five locations to ensure it is properly seated See following WARNING A WARNING e Be sure retaining ring is properly seated in groove If ring is not properly ins
41. before proceeding Performing the procedure without having adequate thread engagement could damage the motor frame end cap or end cap bolts 5 2 Gently tap each bolt alternating between blows until the end cap and motor frame become disen gaged Figure 15b 6 Page 15b 4 6 Remove the two end cap bolts 7 Remove the end cap and armature from the motor frame Figure 15b 7 Page 15b 4 8 Inspect the brush springs for proper tension See Motor Brush Spring and Terminal Insulator Inspection on page 15b 8 9 Remove the armature from the end cap bearing See following CAUTION and NOTE A CAUTION e Removing the armature from the end cap requires two people one to operate the press and another to hold the armature Failure to heed this CAUTION could result in personal injury and or damage to the armature resulting from an unsupported armature falling after it becomes disengaged from the end cap bearing NOTE Replacement of the end cap bearing is recommended if the armature is removed 10 11 12 13 14 15 9 1 Place the end cap in a press with the armature facing down 9 2 Place a bearing press tool with an outer diameter smaller than that of the armature shaft between the press ram and the armature shaft Figure 15b 8 Page 15b 6 9 3 Have an assistant support the armature while the press is activated Inspect the armature for wear and damage See Armature Inspection and Testing on page 15b 6 Inspect
42. brush area or a grounded armature commutator An incor rect reading for the S1 or S2 terminal indicates a possible grounded S1 or S2 terminal or field coil 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15b 1 15B MOTOR MODEL EJ4 4001 Motor TEST PROCEDURE 2 ARMATURE 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 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 the A1 terminal and black probe on the A2 terminal The multimeter should indicate continuity If the reading is incorrect a possible open or poor contact in a brush assembly and or open 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 15b 2 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 2 Disconnect wires from the S1 and S2 terminals on the motor using two wrenches to prevent posts from turning Set a multimeter to 200 ohms and place the red probe on the S1 terminal and the bla
43. clips on the housing ends secure the housing in the hole 2 Hold the bolt 5 and the equalizer bracket 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 wheel brake connect the cable to the brake actuator arm using new clevis pin 2 and new bow tie locking pin 1 Figure 6 20 Page 6 12 5 Place tab 3 on cable housing over the forward leaf spring mounting bolt 2 Figure 6 21 Page 6 12 Install nut 1 Tighten nut to 18 4 ft lb 25 N m 6 Adjust the brakes See Brake Cable Equalizer Adjustment on page 6 9 Page 6 12 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual SECTION 7 STEERING AND FRONT SUSPENSION A DANGER e See General Warnings Section 1 Page 1 1 A WARNING e See General Warnings Section 1 Page 1 1 GENERAL INFORMATION Steering is controlled through a rack and pinion steering assembly that is connected by a steering column to a steering wheel No manual adjustment to the rack and pinion gear assembly is required A spring loaded self adjusting mechanism is incorporated into the assembly STEERING WHEEL See General
44. cluster and brake compo nents 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 6 1 6 WHEEL BRAKE ASSEMBLIES Brake Shoe Removal Brake Shoe Removal Continued 7 Remove brake drums and badly worn brake shoes 7 1 On the back of each brake cluster assembly locate the heads of two brake shoe retainer pins It may be necessary to remove sealant material around the head of each pin 1 2 IN X 5 8 IN COLD CHISEL Figure 6 1 Loosen Turnbuckle Figure 6 2 Shoe Retainer Pins 7 2 Insert a 1 2 inch x 5 8 inch cold chisel under the head of each pin and shear them off as illustrated Figure 6 2 Page 6 2 This will release 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 retaining ring 1 Figure 6 3 Page 6 2 8 2 Pull the axle shaft 2 from the axle tube Figure 6 3 Page 6 2 Figure 6 3 Remove Axle Retaining Ring Page 6 2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Brake Shoe Removal L WHEEL BRAKE ASSEMBLIES i o oa UI st CO oct Q ae C Ar l a slk
45. dash assembly 1 on vehicle Make sure tabs on the forward edge engage to front underbody Secure assembly in place with three screws 2 Figure 4 3 Page 4 5 Tighten screws to 8 8 ft 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 during positioning 3 3 Secure instrument panel to the dash assembly with screws 4 and 5 Tighten screws to 1 8 ft lb 2 5 Nem FLOOR MAT AND RETAINERS See General Warnings Section 1 Page 1 1 The floor mat retainers secure the floor mat to the vehicle and also provide a clean appearance to the side of the vehicle Normally if only the floor mat 3 needs to be removed the screws 2 can be loosened slightly to allow the floor mat to be slid from beneath the retainers 1 Figure 4 4 Page 4 6 oy TRIM CLIPS 4 PLACES Figure 4 4 Floor Mat Retainer Page 4 6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual BODY AND TRIM Kick Plate and Charger Receptacle Bezel FLOOR MAT RETAINER REMOVAL T 2 Remove screws 2 from top of retainer 1 Figure 4 4 Page 4 6 Remove screw 4 from lower rear
46. e Continuity of the wires in the wire harness e Reverse buzzer for proper operation See Test Procedure 16 Reverse Buzzer on page 11 37 e Tow Run switch for proper operation See Test Procedure 6 Tow Run Switch on page 11 19 SPEED CONTROLLER Figure 11 13 Pin 7 Test 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11 27 ELECTRICAL SYSTEM AND TESTING Test Procedures Test Procedure 9E Pins 8 and 16 See General Warnings Section 1 Page 1 1 Pins 8 and 16 in the 16 pin connector provide a connection point for the Forward Reverse rocker switch to the speed controller The switch provides a 48 volt signal to the speed controller through pin 8 when the For ward Reverse switch is in the FORWARD position and provides a 48 volt signal on pin 16 when the Forward Reverse switch is in the REVERSE position 1 2 3 4 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack Position jack stands under the frame crossmember between the spring mount and side stringer just forward of each rear wheel See WARNING Lift only one end in General Warnings Section 1 Page 1 2 Disconnect the 16 pin connector at the speed controller Using a multimeter set for 200 volts DC insert the red probe of
47. e Place Tow Run switch in the TOW position Page 3 2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual GENERAL INFORMATION Storage Es PREPARING THE ELECTRIC VEHICLE FOR EXTENDED OFF SEASON STORAGE 1 Fully charge batteries See Section 13 Batteries 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 1 gallon 3 8 L of water Rinse solution off bat teries Do not allow this solution to enter the batteries Be sure terminals are tight Let the terminals dry and then coat them with Battery Terminal Protector Spray CCI P N 1014305 3 Store vehicle in a cool dry place This will minimize battery self discharge 4 Adjust tires to recommended tire pressure See Section 2 Vehicle Specifications 5 Perform all semiannual periodic lubrication See Periodic Lubrication Schedule Section 10 Page 10 3 6 Thoroughly clean front body rear body seats battery compartment and underside of vehicle 7 Do not engage the park brake Chock the wheels to prevent the vehicle from rolling 8 Keep batteries fully charged during storage 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 electro lyte should be checked monthly to ensure that proper level is maintained AC po
48. 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 to the vehicle storage facility should be sufficient to deliver adequate voltage and current to each charger with all the chargers turned on If not consult your local power company or electrical contractor See Section 14 Battery Charger FLEET ROTATION Rotate vehicle usage It is very hard on batteries if the last vehicles in at night are the first ones out in the morning 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 NOTE When vehicles are being rotated the Club Car CDM Communication Display Module can be a very helpful service tool Monitoring the value of function 3 with the CDM simplifies vehicle usage scheduling See Communication Display Module CDM Section 11 Page 11 38 NUMBERING VEHICLES AND CHARGERS Return the vehicles to the same charger each night if possible If the vehicles are put in a storage facility at random and a vehicle dies while in use and testing shows the batteries are sound then the problem is most likely with the charger However finding the problem charger may
49. from the exposed end of the axle shaft and from the oil seal area prior to installing the axle shaft to prevent oil from coming in contact with brakes 11 Install the rear axle onto the transaxle 11 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 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 11 2 Using 90 internal snap ring pliers 0 090 tip CCI P N 1012560 attach the internal retaining ring into the axle tube hub so that it seats against the axle bearing assembly and into the machined slot in the inside wall of the axle tube hub Figure 16 5 Page 16 3 11 3 Place a 1 4 to 3 8 inch 6 to 10 mm diameter rod against the retaining ring and tap lightly at four or five locations to ensure it is properly seated See following WARNING A WARNING e Be sure retaining ring is properly seated in its groove If ring is not properly installed the axle assembly will separate from the transaxle and damage the axle assembly and other components Loss of vehicle control could result in severe personal injury or death 12 Make sure the drain plug 22 is installed in the transaxle and tightened to 23 ft lb 81 N m Fill the tran saxle through the level indi
50. it slides smoothly and easily Install rubber boot onto backing plate A WARNING e Apply grease carefully when performing the following steps Do not allow any grease to get onto the friction surfaces of the brake shoe pads or the brake drum Failure to heed this warning could 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 grease Dow Corning BR2 Plus or equivalent to each end of both brake shoes and into the slots in the brake shoe mounting block as shown Figure 6 10 Page 6 5 See preceding WARNING BOSSES Figure 6 9 Apply Grease On Bosses Figure 6 10 Apply Grease To Brake Shoes and Slots 6 Use a small brush to carefully apply a light coat of white lithium NLGI 2 grease Dow Corning BR2 Plus or equivalent to the brake adjuster assembly adjuster wheel shoe slots and the shaft of the adjuster wheel as shown Figure 6 11 Page 6 6 See preceding WARNING 7 Install the adjuster wheel 1 and two washers 2 and 3 into the adjuster assembly Figure 6 7 Page 6 4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 6 5 e WHEEL BRAKE A
51. lb 25 N m Position each cover 12 and 13 over its respective support A hole in each cover should be aligned with a corresponding hole in the support Secure the cover to the support with a screw 14 Tighten the screws 14 to 31 in lb 4 6 N m Page 4 18 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual BODY AND TRIM Canopy Two Passenger i 1 otis Od fy o J TYPICAL 4 PLACES TYPICAL D 4 PLACES Zei Aer REF za Cy H AO TER TYPICAL 2 PLACES 2 PLACES ROIO a TYPICAL 4 PLACES 2 PLACES TYPICAL SEATS REMOVED FOR CLARITY el KEE A TYPICAL gt _2 PLACES Kal W ei ki hi 4 Ze TYPICAL 2 PLACES Figure 4 13 Precedent Four Passenger Canopy 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 4 19 BODY AND TRIM Canopy Four Passenger CANOPY FOUR PASSENGER See General Warnings Section 1 Page 1 1 CAUTION e To prevent damage to the canopy do not remove the canopy supports 1 and 6 from the vehicle without first removing the canopy 9 Figure 4 13 Page 4 19 FOUR PASSENGER CANOPY REMOVAL 1 D a p Io Remove the two nuts 12 two bolts 11 and spacers 10 from the canopy 9 and each front canopy support 1 Figure 4 13 Page 4 19 Remove the nuts 14 and bolts 13 from the canopy 9 and the rear support 6 Lift canopy 9 away from front canopy su
52. leaf spring see suspension front and suspension rear lubrication front suspension eee eeeeeeeeneeeeeeeeeeeneeeeeees 7 10 periodic lubrication schedule ee 10 3 transaxle type g cecsccecesceeeessseeeeseceneeeeeeeesees 16 1 M magnet motor speed sensor see motor speed sensor magnet maintenance batteries isang ee an Meee 13 2 periodic lubrication schedule e 10 3 periodic service schedule c cee 10 1 MOOR WEE 5 3 MOTOM siia a ai 11 1 15a 1 15b 1 armature ground test oe eeeeeeeeeeeeeeeeereeeees 15a 6 15b 7 NSpECt On 0 eeeeeeeeseeeeeeceseceeeeeeeeeees 15a 5 15b 6 assembly 0 2 eeeeeeseeeeeeeeeneceeeeeteeeees 15a 10 15b 11 bearing inspection erona neoan an n 15a 7 15b 9 installation enini n a 15a 9 ue VT EE 15a 9 Page i 2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual INDEX braking pedal down motor braking seee 11 1 pedal up motor braking esseere 11 7 brush INSPOCHION 2 2 yl enlace 15b 8 brush spring INSPECTION genni es trea 15b 8 component INSPECCION 2090 ice ENEE geet 15a 7 disassembly scce 15a 4 15b 4 feature Siipien e 11 1 field winding inspection eee 15a 6 15b 8 identification oneee 15a 1 15b 1 installation o e 15a 12 15b 13 Motor Brakihg RE 11 1 protection circuit ee ee eeeeeeeeeeeeeneeeeeeeeeeeneees 11 7 reconditioning eeen 15a 9 15b 11 une EIN 15a 3 15b 2 service specifications
53. level of the plates add just enough water to cover the plates and then charge the batteries After charging fill with water to the level indicator Filling a battery to the level indicator before charging will result in overfilling because the electrolyte level will rise during charging and some of the electrolyte may bubble out of the cap This reduces the battery s capacity and corrodes the metal parts around it 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 13 3 BATTERIES Battery Charging Electrolyte Level Continued The electrolyte level should be checked weekly to be sure electrolyte is at its proper level Figure 13 2 Page 13 3 Never allow the electrolyte level to fall below the tops of the plates because this will cause the exposed part of the plate to become permanently inactive For best results use a battery watering gun to add water to batteries Check the electrolyte level more frequently in hot weather or when batteries are old MINERAL CONTENT For the longest battery life use distilled water in batteries However if tap water is to be used be sure the min eral contents are below these levels IMPURITY E Suspended matter Trace Total solids 100 0 ely and Magnesium 40 0 Iron 5 0 Ammonia 8 0 Organic matter 50 0 Nitrates 10 0 Nitrites 5 0 Chloride 5 0 VIBRATION DAMAGE The battery hold downs should always be tight enough to kee
54. liters 67 liters Engine crankcase without filter Engine crankcase with filter Unitized transaxle Fuel tank TIRE PRESSURE 18 20 psi 18 20 psi Front and rear 1 24 1 38 1 24 1 38 bars bars SECTION 3 GENERAL INFORMATION A DANGER e See General Warnings Section 1 Page 1 1 A WARNING e See General Warnings Section 1 Page 1 1 Important features unique to the different models covered in this manual are highlighted Club Car Inc rec ommends the owner operator read and understand this manual and pay special attention to features specific to their vehicle s Refer to the owner s manual provided with the vehicle for information on the following topics e Pre Operation and Daily Safety Checklist e Controls and Indicators e Driving Instructions e Towing e Transporting on a Trailer e Subsequent Owner Registration e Warranties SERIAL NUMBER IDENTIFICATION The serial number of the vehicle is printed on a bar code decal mounted on the passenger side inner dash Figure 3 1 NOTE Always have the vehicle serial number available when ordering parts or making inquiries Club Car SERIAL NUMBER BOX 2 rose PQ0501 123456 AUGUSTA G Figure 3 1 Serial Number Decal 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 3 1 Ea GENERAL INFORMATION Safety Committee SAFETY COMMITTEE If the golf car is to be rented or is part of a fleet we strongly recomm
55. mechanism A WARNING e Reduced braking force could result if the jam nuts are not tightened in the proper sequence 4 Once steps 2 and 3 are complete recheck the 2 inch specification listed in step 1 If the measurement has not changed the adjustment is complete If the measurement has changed perform steps 1 through 3 again 5 Replace access panel and floor mat 5 1 Place floor cover plate 7 over the floor opening See Figure 5 2 Section 5 Page 5 2 5 2 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 See Figure 5 1 Section 5 Page 5 1 BRAKE CLUSTER REMOVAL AND INSTALLATION See General Warnings Section 1 Page 1 1 See also Warning on Page 6 1 Brake Cluster Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Place chocks at the front wheels and loosen the lug nuts on the rear wheels Lift the rear of the vehicle with a chain hoist or floor jack Place jack stands under the axle tubes to support the vehicle See WARN ING Lift only one end in General Warnings Section 1 Page 1 2 3 Gain access to the pedal group by removing the floor mat and access panel See Pedal Group Removal Section 5 Page 5 1 4 Loosen the two jam nuts 1 and 3 on either side of turnbuckle 2 Figure 6 1 Page 6 2 Note that the fo
56. ommended A soft bristle brush may be used if necessary Wipe off any residue with a water dampened cloth Difficult Stains Dampen a soft white cloth with a solution of 10 household bleach sodium hypochlorite and 90 water Rub gently to remove stain then rinse with a water dampened cloth to remove bleach concentration More Difficult Stains Perform previous procedure using full strength bleach or allow bleach to pud dle on affected area for approximately 30 minutes Rinse with a water dampened cloth to remove any remaining bleach concentration CAUTION e To prevent damage to the vehicle when removing difficult stains or heavy soiling remove the seat bottom from the vehicle first 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 4 1 BODY AND TRIM Front and Rear Body Repair FRONT AND REAR BODY REPAIR See General Warnings Section 1 Page 1 1 STRESS LINES OR STREAKS Repeatedly flexing the Surlyn body can cause white stress lines or streaks in the finish To remove them 1 2 3 Hold a heat gun 12 inches 30 cm away from the affected area with the gun on its lowest heat setting Slowly wave the heat gun back and forth over the affected area until the streak fades It may be necessary to move the gun closer to the body to fade the streak but under no circumstance should the gun be held closer than 6 inches 15 cm to the body CAUTION e Holding the heat gun too close to th
57. 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 15b 11 When replacing brushes replace all four brushes Never replace only two Install the brushes in the same rigging 180 apart from each other Brush Inspection 1 2 Remove the motor from the vehicle See Motor Removal on page 15b 2 Remove the end cap and armature by performing steps 1 through 7 of Motor Disassembly on page 15b 4 Inspect the brushes 13 for damage or excessive wear Figure 15b 15 Page 15b 10 Replace brushes if required See preceding NOTE Use dial calipers or a micrometer to measure the brush length The minimum allowable brush length is 0 62 inches 16 mm Replace the set of brushes as required See preceding NOTE Page 15b 8 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual MOTOR MODEL EJ4 4001 Motor Component Testing and Inspection Terminal Insulator Inspection 1 Remove the motor from the vehicle See Motor Removal on page 15b 2 2 Remove the terminal insulators by performing steps 1 through 12 of Motor Disassembly on page 15b 4 1 Inspect the insulators 4 and 6 for cracks or other damage Figure 15b 15 Page 15b 10 Replace insulators as required Bearing Inspection NOTE Replacement of the end cap bearing is highly recommended if the end cap is removed from the motor The follo
58. only one end in General Warnings Section 1 Page 1 2 3 Place a floor jack under the transaxle and raise the rear of the vehicle Position jack stands under the alu minum frame rails forward of the spring mount Lower the vehicle to let the jack stands support the vehi cle Figure 16 6 Page 16 5 See WARNING Lift only one end of the vehicle in General Warnings Section 1 Page 1 1 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 4 Figure 16 7 Page 16 5 AS SEEN FROM DRIVER SIDE OF AS JACK STAND UNDER ALUMINUM FRAME RAIL Figure 16 6 Vehicle Supported on Jack Stands Remove bolt then rotate shackle up and away from spring Figure 16 8 Disconnect Shocks Figure 16 9 Shackles 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 16 5 TRANSAXLE TYPE G Transaxle Transaxle Removal Continued 6 7 8 Disconnect the shock absorbers from their lower mounts Figure 16 8 Page 16 5 Disconnect the four motor wires Use two wrenches to prevent the post from turning With a floor jack supporting the transaxle remove lower spring shackle nuts and bolts Position shackles so they are clear of springs Figure 16 9 Page 16 5
59. or damaged remove them and press in new ones KINGPIN AND STEERING SPINDLE INSTALLATION 1 Inspect all parts and replace them as necessary 2 Install the kingpin 7 over the leaf spring eye Insert the bolt 8 Figure 7 19 Page 7 16 Tighten the bolt to 17 ft lb 23 N m 3 Install the wave washer 6 on the kingpin 4 Install the steering spindle on the kingpin Place upper clevis over the kingpin threads and install conical washer 2 and nut 1 Tighten the nut to 50 ft lb 68 N m 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 7 13 STEERING AND FRONT SUSPENSION Front Suspension Components Kingpin and Steering Spindle Installation Continued 5 Attach the tie rod ends 12 to the spindle tabs than install and tighten the nuts 14 to 70 ft lb 95 N m Install the retaining pins 15 Figure 7 18 Page 7 15 6 Install front hub and wheel See Hub Installation on page 7 17 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 Remove wheel Remove bolts 17 and move rack and pinion to allow clearance for bolt 19 Figure 7 18 Page 7 15 Remove bolts 11 and 19 Remove the control arm 6 om Fo Inspect the bushings 7 and sleeves 8 and 9 in the control arm and replace them if necessa
60. orientation of the batteries and the connecting wires Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warn ings Section 1 Page 1 1 Remove remaining wires and batteries See Wiring Diagrams Section 11 Page 11 2 2 Visually inspect the new batteries for any damage that may have occurred in transit 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 13 1 BATTERIES Battery Care Battery Replacement Continued 3 If the battery cables are to be reused inspect them for broken or frayed wires damaged terminals or worn insulation Remove any corrosion on the connectors A solution of baking soda and water 1 cup 237 mL baking soda per 1 gallon 3 8 L of water does an excellent job of neutralizing and removing the corrosion Be careful not to allow the baking soda solution to enter the battery BATTERY BANK Figure 13 1 IQ System Battery Configuration 4 Check and clean the battery rack and hold downs The nuts and bolts on the hold downs may corrode It is therefore advised they be cleaned periodically and replaced as necessary 5 Install batteries in the proper orientation Figure 13 1 Page 13 2 Install battery hold downs The hold downs should be tight enough so batteries do not move while vehicle is in motion but not so tight as to crack or buckle battery case Tighten to 97 4 in lb 11 N m alternating between hold down bolts
61. punctures tears eeen 4 2 minor impact damage deformations 4 2 minor scratches and surface blemishes 4 2 stress lines or streaks ccccceeeeseeeeeeeteeeee 4 2 UO eetsie dete hn el hota Etat ices 8 2 reverse buzzer instalation eien Sheed ets 12 8 Felsen Ee E edad oth dbeshite 12 8 TESTING sheet eo Ee A ee 11 37 S Satety ge Eet 1 1 2 1 Safety committee cc eeseeeseeceeeeeeeeeeseeeeeeeeeees 3 2 SAM Installation EE 4 10 FeMOVal witht aa ale Cte 4 10 seat back four passenger NEE Ire RE 4 13 El ue EE 4 12 seat support four passenger installation e Set See Deeg eeng 4 13 Tue EE 4 13 INDEX serial number vehicle cccccccccccceeeeeeeeees 3 1 service schedule see periodic service schedule see also periodic lubrication schedule shock absorber see suspension front and suspension rear solenoid ET Le EE 12 12 ul VE 12 12 TESTING EE 11 35 solenoid activating coil TESTING Ae ee N 11 16 speed controller connector 16 pin see test procedures installation r heen eed EES 12 11 En e 12 11 speed sensor see motor speed sensor steering rack and pinion El 7 8 disassembly ciii iratis tner 7 7 installation asn a 7 9 POMOVAl sor ced deere hae aeons teers 7 4 steering COLUMN eerren 7 2 CISASSEMDIY E 7 4 ET Le EE 7 4 E ul EE 7 2 steering wheel installation gouv ee ial 7 2 reMmoOVal cise Ee 7 1 storage electric vehicle cececceceseeeeeeecee
62. reading is incorrect a pos sible open or poor contact in a brush assembly and or open 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 15a 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 Using two wrenches to prevent the post from turning disconnect wires from the F1 and F2 terminals on the motor Using a multimeter set to 200 ohms place the red probe on the F1 terminal and the black probe on the F2 terminal The multimeter should indicate continuity If the reading is incorrect a pos sible open field coil or bad connections at the terminals may be the cause The motor will need to be removed from the vehicle and repaired by a qualified technician See Motor Removal on page 15a 3 Page 15a 2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual 15A MOTOR MODEL 5BC59JBS6365 External Motor Testing MOTOR See General Warnings Section 1 Page 1 1 Motor Removal 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 Label the wires
63. servicing Club Car vehicles and to protect the vehicles from possible damage resulting from improper service or maintenance the procedures in this manual must be followed It is important to note that throughout this manual there are statements labeled DANGER WARNING or CAU TION These special statements relate to specific safety issues and must be read understood and heeded before proceeding with procedures There are statements labeled NOTE which provide other essential ser vice or maintenance information A DANGER e A DANGER indicates an immediate hazard that will result in severe personal injury or death A WARNING e A WARNING indicates an immediate hazard that could result in severe personal injury or death A CAUTION e A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result in minor personal injury CAUTION e 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 statements appear throughout this manual and on the vehicle A DANGER e Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed area Wear a full face shield and rubber gloves
64. shaft Figure 15b 21 Page 15b 13 2 4 The grease should be evenly distributed in the grooves to a width of approximately 3 8 inch 9 5 mm 2 5 Use a flat screwdriver to clean the grease out of one of the grooves and allow air to escape when the motor is pushed onto the input shaft GREASE L 1 8 INCH 3 8 INCH 9 5 MM 3 1 MM Figure 15b 20 Grease on Putty Knife Figure 15b 21 Application of grease to Input Shaft Grooves 2 6 Check the chamfer and end of the input shaft to ensure these areas are completely clean of grease as shown Figure 15b 22 Page 15b 14 3 Install the molded bumper 3 1 With the flat side toward the bottom of the coupling install the molded bumper 30 into the motor coupling Figure 15b 15 Page 15b 10 See following NOTE NOTE The motor coupling and the new molded bumper must be free of grease and debris 3 2 Ensure that the installed bumper is seated at the bottom of the coupling 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15b 13 15B MOTOR MODEL EJ4 4001 Motor Installation Motor Installation Continued 4 Install motor on transaxle 4 1 NOTE Slide the motor coupling onto the transaxle input shaft See following NOTE The coupling will push any excess grease on the input shaft along the shaft toward the transaxle When the motor is pushed onto the input shaft the motor housing will not bott
65. should be used to press the bear ing onto the armature 2 Install the speed sensor magnet See Speed Sensor Magnet Installation on page 15a 9 SPEED SENSOR MAGNET INSPECTION Inspect the speed sensor magnet 18 for rust wear and cracks Figure 15a 10 Page 15a 8 Replace the magnet if necessary SPEED SENSOR MAGNET REMOVAL 1 To remove the speed sensor magnet 18 remove the motor bearing Figure 15a 10 Page 15a 8 See Bearing Removal on page 15a 9 SPEED SENSOR MAGNET INSTALLATION 1 Using a solid bearing driver with a diameter of no less than 1 inch 2 54 cm press the motor speed sen sor magnet 18 onto the shaft until the magnet hub is flush with the armature shaft RECONDITIONING THE MOTOR See General Warnings Section 1 Page 1 1 Motor reconditioning must be performed by a qualified motor repair technician The use of proper tools and procedures is absolutely essential for successful motor reconditioning 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15a 9 15A MOTOR MODEL 5BC59JBS6365 Motor Specifications Motor Assembly Any rework must be performed by a qualified technician Motor service specifications are listed in the follow ing table ITEM SERVICE LIMIT Commutator diameter minimum 2 265 in 66 675 mm Commutator concentric with armature shaft within 0 001 in 0 0254 mm Limit depth of cut when machining commutator 0 00
66. 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 just forward of each spring mount See WARNING Lift only one end in General Warnings Section 1 Page 1 2 3 Disconnect the 16 pin connector at the speed controller 4 Using a multimeter set for 20k ohms insert the red probe of the multimeter into pin 2 yellow wire of the 16 pin connector See following CAUTION Insert the black probe into pin 3 purple wire of the 16 pin connector Figure 11 10 Page 11 24 CAUTION e 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 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 floor the multimeter should indicate between 5 67k ohms and 7 43k ohms 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11 23 ELECTRICAL SYSTEM AND TESTING Test Procedures Test Procedure 9A Pins 1 2 and 3 Continued 10 20k OHM SETTING READING WITH PEDAL NOT PRESSED Figure 11 1
67. technician The use of proper tools and procedures is absolutely essential for successful motor reconditioning Motor Specifications Any rework must be performed by a qualified technician Motor service specifications are listed in the follow ing table ITEM SERVICE LIMIT Commutator diameter minimum 2 80 in 71 10 mm Commutator concentric with armature shaft within 0 003 in 0 08 mm exceed Bar to bar runout should not 0 005 in 0 013 mm Undercut of segment insulator after machining commutator 0 040 in 1 0 mm Armature resistance at 0 012 ohms between 75 F 24 C bar 1 and bar 15 Field coil resistance at 75 F 24 C 1 75 ohms MOTOR ASSEMBLY See General Warnings Section 1 Page 1 1 1 Replace the bearing 1 1 1 2 Use an arbor press to install a new bearing into the end cap To help avoid damaging the bearing apply pressure only to the outer race when installing the bearing Install the retaining ring to secure the bearing Figure 15b 11 Page 15b 6 2 Install the brushes and brush rigging See following NOTE NOTE When installing new brushes remove and replace brushes one at a time This method ensures the 2 1 2 2 2 3 2 4 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 same rigging 180 apart from each other
68. the Forward Reverse switch in the NEUTRAL position 3 Connect the IQDM to the vehicle as described in the IQDM Owner s Manual 4 Test the key switch 4 1 Access the Test menu and select KEY INPUT by using the SCROLL DISPLAY buttons The IQDM should indicate OFF when the key switch is in the OFF position Page 11 20 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL SYSTEM AND TESTING Test Procedures 4 2 While monitoring the IQDM display screen turn the key switch to the ON position The IQDM should indicate ON 4 3 Ifthe IQDM does not indicate that KEY INPUT is ON when the key switch is in the ON position pro ceed to the following procedure Key Switch and MCOR Limit Switch Circuit Test without the IQDM Handset If the key switch functions as described proceed to the following step See following NOTE NOTE The key switch MUST function properly in order to test the MCOR limit switch with the IQDM handset 5 Test the MCOR limit switch 5 1 Select FOOT INPUT on the Test menu 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 switch in the ON position press the accelerator pedal The IQDM should indicate that FOOT INPUT is ON when the accelerator pedal is pressed 6 If any reading is obtained that is not described in steps 4 and 5 perform
69. the OBC 4 Remove the wedge lock from the six pin connector housing that is connected to the vehicle wire harness Remove the brown white wire from the connector plug 5 Using a jumper wire with an alligator clip at each end connect one alligator clip to the negative post of battery no 1 and the other alligator clip to the brown white wire terminal socket that was removed from the six pin connector plug 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 LOW BATTERY TH INDICATOR ANT men n WINDOW COMMUNICATION Ai DISPLAY MODULE sec DISPLAY FUNCTIONS RESS AND HOLD UTTON TO SHOW SE BUTT BUTTON unc cle une une lete POWER e ox Club Car OFF H PART 17075 Figure 11 19 CDM The CDM can be used to retrieve from the onboard computer four important items of information that can be useful in troubleshooting the IQ System vehicle To access one of these items the item s corresponding Func tion Code must be selected on the CDM This is done by pressing the Function Button until the desired func tion code is displayed in the window See Figure 11 19 Page 11 38 for CDM features Releasing the button when the desired code is displayed will
70. the black probe to the negative post of battery no 4 and connect red probe with insulation piercing probe on the pink wire close to the connector on the Tow Run switch A WARNING e 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 Tow Run switch in the RUN position the reading should be approximately 48 50 volts With the switch in the TOW position the reading should be below approximately 5 volts 3 If the reading is above 5 volts with the switch in the TOW position replace the switch 4 Ifthe reading is below 5 volts with switch in the RUN position check continuity of the blue 18 gauge wire from the large post of the solenoid to the connector at the Tow Run switch 5 If the continuity readings are correct replace the Tow Run switch 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11 19 ELECTRICAL SYSTEM AND TESTING Test Procedures TEST PROCEDURE 7 BATTERY PACK VOLTAGE UNDER LOAD See General Warnings Section 1 Page 1 1 1 Be sure the batteries are fully charged and that the electrolyte level is correct in all cells 2 Connect the tester leads to the positive post of battery no 1 and negative post of battery no A OF VEHICLE Figure 11 9 Page 11 20 BLACK PROBE TO BATTERY NO 4 RED PROBE TO BATTERY NO 1 Figure 11 9 Battery Discharge Test Tur
71. the following steps 6 1 Check the wiring of the key switch and MCOR See Wiring Diagrams on page 11 2 6 2 Check the continuity of the key switch wires and the MCOR limit switch wires 7 lf the problem was not found proceed to the following procedure Key Switch and MCOR Limit Switch Circuit Test without the IQDM Handset on page 11 21 Key Switch 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 See WARNING Lift only one end in General Warnings Section 1 Page 1 2 3 Turn the key switch to the OFF position and place the Forward Reverse switch in the NEUTRAL position 4 Test the key switch 4 1 Remove the instrument panel See step 2 of Key Switch Removal Section 12 Page 12 1 4 2 Using a multimeter set to 200 ohms place the red probe on the key switch terminal with the blue wire Place the black probe on the other key switch terminal 4 3 With the key switch in the OFF position the multimeter should indicate that continuity is not present 4 4 With the key switch in the ON position the multimeter should indicate that continuity is present 4 5 If any other reading is obtain
72. the motor frame and field windings See Motor Frame and Field Windings Inspection on page 15b 8 Remove the brush rigging 12 1 Mark the brush terminal posts A1 and A2 12 2 Remove the two nuts securing the brush terminals A1 and A2 to the end cap Figure 15b 9 Page 15b 6 12 3 Remove the two screws and the brush rigging to the end cap Figure 15b 10 Page 15b 6 Inspect the terminal insulators See Terminal Insulator Inspection on page 15b 9 Remove the bearing from the end cap 14 1 Remove the retaining ring that secures the bearing in the end cap Figure 15b 11 Page 15b 6 14 2 Use an arbor press to remove the bearing from the end cap Inspect the bearing for wear and damage See Bearing Inspection on page 15b 9 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15b 5 15B 15B MOTOR MODEL EJ4 4001 Motor Component Testing and Inspection Figure 15b 11 Bearing Retaining Ring MOTOR COMPONENT TESTING AND INSPECTION See General Warnings Section 1 Page 1 1 ARMATURE INSPECTION AND TESTING 1 Remove the motor from the vehicle See Motor Removal on page 15b 2 2 Remove the end cap and armature by performing steps 1 through 7 of Motor Disassembly on page 15b 4 Visual Inspection e Burned charred or cracked insulation e Improperly cured varnish e Thrown solder e Flared armature windings Page 15b 6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual
73. the speed controller Figure 11 12 Page 11 26 A CAUTION e Do not fully insert probes into the 16 pin plug Doing so can result in a poor connection Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten battery terminals to 110 in Ib 12 4 N m Place the Tow Run switch in the RUN position key switch in the ON position and Forward Reverse switch in the FORWARD position 7 The multimeter should indicate zero volts DC at this time 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 11 12 13 The multimeter should indicate full battery voltage approximately 48 volts when the accelerator pedal is pressed While observing the multimeter release the accelerator pedal The multimeter should indicate zero volts when the accelerator pedal is not pressed 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 33 Tow Run switch for proper operation See Test Procedure 6 Tow Run Switch on page 11 19 Key switch and MCOR limit switch for proper operation See Test Procedure 8 Key Switch and MCOR Limit Switch Circuit on page 11 20 Page 11 26 20
74. 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 2 07 2 42 Bars The three point contact wall floor and hand will help ensure that beads snap into place and form a proper seal as tire is inflated Figure 8 2 Page 8 4 See following WARNING A WARNING Do not use a compressed air source with pressure over 100 psi 6 90 Bars Due to low pressure requirements of a small tire over inflation could be reached almost instantly with a high pressure air supply Over inflation could cause tire to explode possibly resulting in severe personal injury 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 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 8 3 ER WHEELS AND TIRES Tires Figure 8 2 Inflate Tire Page 8 4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual SECTION 9 REAR SUSPENSION A DANGER e See General Warnings Section 1 Pag
75. to ensure proper reconnection 3 Slightly loosen all the lug nuts on both rear wheels 4 Place floor jack under transaxle and raise rear of vehicle Figure 15a 2 Page 15a 3 then place jack stands under frame crossmember between the spring mount and the side stringer just forward of each rear wheel Lower the vehicle to let the jack stands support the vehicle Figure 15a 3 Page 15a 3 See following WARNING A WARNING e Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 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 the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes JACK STAND UNDER ALUMINUM FRAME RAIL Figure 15a 2 Lift Vehicle with Floor Jack Figure 15a 3 Vehicle Supported on Jack Stands 5 Remove both rear wheels 6 Remove the nut cup washer and bushing from the bottom side of the shock absorber Compress the shock absorber pushing upwards to move it out of the way Figure 15a 4 Page 15a 4 7 Remove the nuts and bolts mounting the rear leaf springs to the shackles
76. wall of the axle tube hub Figure 16 5 Page 16 3 If the retaining ring 6 axle bearing 5 or sleeve 4 must be replaced the entire axle shaft assembly 1 or 2 must be replaced Figure 16 5 Page 16 3 Place a 1 4 to 3 8 inch 6 to 10 mm diameter rod against the retaining ring and tap lightly at four to five locations around the retaining ring to ensure it is properly seated See following WARNING A WARNING e Be sure the retaining ring is properly seated in its groove If the ring is not properly installed the axle assembly will separate from the transaxle and damage the axle assembly and other components Loss of vehicle control could result causing severe personal injury or death 3 If anew oil seal was installed allow 24 hours before operating the vehicle to allow the Loctite 603 to fully cure AXLE BEARING Do not remove the axle bearing 5 from a Type G transaxle If bearing is worn or damaged the entire axle assembly 1 or 2 must be replaced Figure 16 5 Page 16 3 Page 16 4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual TRANSAXLE TYPE G Transaxle TRANSAXLE See General Warnings Section 1 Page 1 1 TRANSAXLE REMOVAL 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Place chocks at the front wheels and slightly loosen lug nuts on both rear wheels See WARNING Lift
77. when working on or near batteries e Battery Poison Contains acid Causes severe burns Avoid contact with skin eyes or clothing Antidotes External Flush with water Call a physician immediately Internal Drink large quantities of milk or water Follow with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 1 1 SAFETY General Warnings A WARNING Place Tow Run Remove negative LC switch in TOW cable first Only trained technicians should service or repair the vehicle or battery charger Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair The appropriate instructions must be used when performing maintenance service or accessory installation Follow the procedures exactly as stated in this manual and heed all DANGER WARNING and CAUTION statements in this manual as well as those on the vehicle and battery charger Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 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 the wheels that remain on the floor When not performing a test or service p
78. 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 15a 10 Page 15a 8 There will be approximately 1 16 inch 1 6 mm gap between the motor adapter ring and transaxle housing as shown Figure 15a 17 Page 15a 13 CHAMFER SHAFT END Figure 15a 16 Clean Chamfer and Input Shaft End Figure 15a 17 Gap at Motor and Transaxle 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15a 13 15A 15A MOTOR MODEL 5BC59JBS6365 Motor Installation Motor Installation Continued 4 2 Loosely install four motor bolts and washers that secure the motor to the transaxle Do not tighten 4 3 Begin finger tightening the bolts 1 and 2 in the sequence indicated Figure 15a 19 Page 15a 15 Continue tightening by hand until the motor is seated in the transaxle housing See following CAU TION and NOTE CAUTION e 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 noise during operation 4 4 Tighten the right bolt 1 to 65 in Ib 7 3 N m 4 5 Tighten the left bolt 2 to 65 in lb 7 3 N m 4 6 Tighten the center bolt 3 to 65 in lb 7 3 N m Figure 15a 19 Page 15a 15 4 7 Tighten the bolt
79. wire with an alligator clip between the B terminal of the speed controller use alligator clip for this connection and pin 12 blue white wire of the 16 pin connector Figure 11 17 Page 11 32 See following CAUTION CAUTION e 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 first Tighten battery terminals to 110 in lb 12 4 N m 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11 31 ELECTRICAL SYSTEM AND TESTING Test Procedures Test Procedure 9H Pin 12 Continued SPEED CONTROLLER 6 7 8 Figure 11 17 Pin 12 Test Place the Tow Run switch in the RUN position and the key switch in the ON position The solenoid should click when the key switch is placed in the ON position If any other activity is observed check the following items e Continuity of the wires in the wire harness e Reverse buzzer for proper operation See Test Procedure 16 Reverse Buzzer on page 11 37 e Tow Run switch for proper operation See Test Procedure 6 Tow Run Switch on page 11 19 e Key switch for proper operation See Test Procedure 8 Key Switch and MCOR Limit Switch Cir cuit on page 11 20 e Solenoid for proper operation See Test Procedure 14 Solenoid Continuity on page 11 35 TEST PROCEDURE 10 ONBOARD COMPUTER SILICON CONTROLLED REC
80. wiring and wire harness is properly routed and secured Failure to properly route and secure wiring could result in vehicle malfunction property damage personal injury or death For many tests the electronics module 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 6 Page 11 13 See following WARNING A WARNING e 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 completely COMPONENT MOUNTING Figure 11 6 Electronic Module Cover After test procedures are completed be sure to replace the cover See following CAUTION CAUTION e Exposure to water may damage electronic components Do not operate vehicle without the cover properly installed Do not direct a water stream in area of the cover 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11 13 ELECTRICAL SYSTEM AND TESTING INDEX OF TEST PROCEDURES 8 9 Batteries Voltage Check Onboard Computer Solenoid Lockout Circuit Solenoid Activating Coil MCOR Voltage A1 and A2 Motor Voltage Tow Run Switch Battery Pack Voltage Under Load Key Switch and MCOR Limit Switch Circuit 16 Pin Connector 10 Onboard Computer Silicon Controlled Re
81. 0 Pins 1 2 and 3 Test Using a multimeter set for 20k ohms insert the red probe of the multimeter into pin 2 yellow wire at the 16 pin connector Connect the black probe into pin 1 white black wire See previous CAUTION With the accelerator pedal fully up not pressed the multimeter should indicate between 5 67k ohms and 7 43k ohms Slowly press the accelerator pedal while monitoring the multimeter The resistance should drop as the pedal is pressed When the pedal is all the way to the floor the multimeter should indicate approximately 1k ohms If any other reading is observed check the continuity of the wires in the wire harness Test Procedure 9B Pin 5 See General Warnings Section 1 Page 1 1 Pin 5 in the 16 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 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 See WARNING Lift only one end in General Warnings Section 1 Page 1 2 Disconnect the 16 pin connector at the speed controller Using a multimeter set for 200 volts DC insert the red probe of the multimeter into pin 5 light blue wire of the
82. 05 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL SYSTEM AND TESTING Test Procedures Test Procedure 9D Pin 7 See General Warnings Section 1 Page 1 1 Pin 7 in the 16 pin connector provides a connection point for the reverse buzzer 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 just forward of each spring mount See WARNING Lift only one end in General Warnings Section 1 Page 1 2 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 7 orange white wire of the 16 pin connector Figure 11 13 Page 11 27 See following CAUTION CAUTION e 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 first Tighten battery terminals to 110 in lb 12 4 N m 6 Place the Tow Run switch in the RUN position 7 The reverse buzzer should sound when the Tow Run switch is in the RUN position 8 If any other activity is observed check the following items
83. 1 270 1 275 1 265 Cell 4 Negative Post 1 275 1 270 1 285 1 265 Cell 5 1 270 1 265 1 280 1 270 Cell6 1 275 1 280 1 280 1 260 After the hydrometer test it appears that battery no 1 is the problem Next the discharge test was performed Discharge test results BATTERY NO 1 2 3 4 Discharge Voltage 8 16 V 10 99 V 11 60 V 10 72 V After a discharge 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 amps after a full charge After confirming there were no problems with the electrical system charger or brakes the on charge voltage was recorded as follows BATTERY NO 1 2 3 4 15 80 V On Charge Voltage 15 72 V 14 66 V 15 85 V Battery no 2 was immediately suspected as the problem After checking battery no 2 with a hydrometer it was discovered that the negative post cell was completely dead Battery no 2 should be replaced with a bat tery that has the same age and usage as the other batteries in the set 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 13 11
84. 12 3 ele LEE 12 3 TeSUING eege ite ee AER 11 38 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual bearing axle see transaxle type g axle bearing bearing motor see motor bearing body TEE 4 4 4 8 see also repair front and rear body Installation tee eee ead Die helt 4 4 ue EE 4 4 body rear see also repair front and rear body removal yers erpii seris edE d DEER 4 8 brake return Spring eeen 5 3 brakes ACJUSIMEN sepini enioia isece esris 6 9 cable Installation erena eee 6 12 removal rann atih the enee 6 11 cleaning assembly AA 6 5 cluster ETH Tri IM 6 10 removal E 6 9 shoe IM Stall AON geg eek fasts aeden sees T 6 6 fOMOVAl agefuer ste Sien nese tat 6 1 braking motor see regenerative braking braking regenerative see regenerative braking bumper fronts ee asin 4 4 CG canopy four passenger instalation sa e e a 4 20 FOMOVAl setio nn i e a ata 4 20 canopy two passenger instalation siegi ree ea e a 4 18 removal amina Ee ee tact 4 16 CAUTION CETINIMON Ree 1 1 charger bezel REENEN 4 7 charger receptacle THE 12 14 nstallat O icant eee hs 12 14 FOMOVAl EEE EEE ETA 12 14 TESTING Ariran on cone 11 33 charger receptacle bezel instalation sise a EH 4 7 Tute LEE 4 7 cleaning brake assembly AA 6 5 vehicle Dody EE 4 1 column steering see steering column communication display module CDM lee CodeS redieri niin aiena 11 38 retrieving data from ceecee 11 39 troubleshootin
85. 16 pin connector See following CAUTION Using an alligator clip connect the black probe to the B terminal of the speed controller Figure 11 11 Page 11 25 CAUTION e Do not fully insert probes into the 16 pin plug Doing so can result in a poor connection Page 11 24 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL SYSTEM AND TESTING Test Procedures SPEED CONTROLLER 200 DCV SETTING READING WITH OBC POWERED UP AND BATTERY CHARGER DISCONNECTED Figure 11 11 Pin 5 Test 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 Place the Tow Run switch in the RUN position The multimeter should indicate zero volts DC at this time While monitoring the multimeter plug the battery charger into the vehicle charger receptacle Oo MO N o After a short delay the onboard computer should power up come out of sleep mode charger relay should click and the ammeter on the charger should indicate that the vehicle batteries are being charged 10 The multimeter should indicate zero volts DC while the charger is connected to the vehicle 11 While observing the multimeter disconnect the DC plug from the vehicle charger receptacle 12 The multimeter should indicate full battery voltage when the charger is not connected to the vehicle 13 If any other reading is obtained check the f
86. 2 Onboard Computer OBC vaea aaan naasna annaa anea aaa ae aaa aaea a eaa A a aa AEE NEE aE EEEE 12 13 Charger Receptacle ssrin aa a aaa aa A a E aa inc aaa aa aa aaia 12 13 SECTION 13 BATTERIES General MOMMALION EE 13 1 Battery Replacement was giegeeeeg Segegen eg deeg dd Eege detes tec ANANI RARAP AIA AAE PAAANO ARASINI SAAE AREAS ESES 13 1 BatteryCale cisco heibei eege deed ina ett ee ha eae 13 2 Preventive Maintenance cccecceecceeeeeeeeeceeeeeeeeeeeeeeeeceeseseeeaeeeeeeeaaaeseseeaaeeeeseeaaeseeeeeseneeeneeneaeeees 13 2 SEl DISCHAQS EE 13 3 Electrolyte Level dees geed NEE Dee de dee eege e e 13 3 Minefal Comte nt zegin Seed EE Seege Seed 13 4 MAD reat i E ue EE 13 4 Battery Ano ae EE 13 4 Charger Shuts Off After 16 Hours c ccccceeeeeseseeeceneeeseeeeceeaeeeeeaeeceaeeeeeeaeeseaaeeesaaeeseeeeeesiaaeseeneeeaas 13 5 Deep Discharge sec cc esse geg e cage ARNEE AE pe dee eo ee eee dea de 13 5 Early Excessive Discharging ceccceceeeeeeeceeeeeeeeeeeeeseneeeeeeeeeaeeeeeeeeaeeeeeeeseaeeeeeeseeeeeeeseeeeaeeeeseeeaeeees 13 5 InGoming ee 13 5 Fleet Rotation acc Ace niente ee ihn ae Ae i ate ae ea cata 13 5 Numbering Vehicles and Chargers c cccccscceceeeeeeeeneeececeeeesaaeeseeeeesaaaeseeeeeesaeesseneeeseieeeesnaeessaes 13 5 Battery Troubleshooting Chart 0 c cccccccceceeeeceeeeeeceaeeeeaeeeseeaeeesaaeeseeeeesaaaeeseeeeesaaesdeeeeesiaeeseiaeessaes 13 6 Battery Testing DEE 13 7 Battery Charger
87. 5 in 0 127 mm Bar to bar runout should not exceed 0 002 in 0 00508 mm If undercut of segment insulator is less than 0 016 inch 0 406 mm it should be undercut to 0 031 in 0 8 mm Machined face of commutator 8 16 microinches 203 2 406 4 nm Field coil resistance IQ System 3 20 hp 1 61 ohms MOTOR ASSEMBLY See General Warnings Section 1 Page 1 1 1 If the bearing has been removed replace the bearing See Bearing Installation on page 15a 9 2 Install the brushes 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 properly positioned in the rigging Refer to Motor Assembly for brush installation See Motor Assembly on page 15a 10 When replacing brushes replace all four brushes Never replace only 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 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 15a 12 Page 15a 12 Tighten the screws to 20 in lb 2 3 N m 2 2 One at atime push brush spring extensions back from brushes and slide the brushes back until they are completely retracted into their mounting slots
88. BLUE 12 BLACK SONIC WELD 12 BLACK 16 TAN 16 RED 8808008080800689 18 ORANGE 18 BLUEWHITE 16 BLUE 16 BLKWHT e e BRAKE LIGHT SWITCHES 16 GREEN 18 PURPLE 18 BROWN WHITE 18 WHITE 18 WHITE 16 RED 16 PINK 16 PINK SONIC WELD 16 RED 16 RED 18 RED SOLENOID fy Ze KS 6 YELLOW 18 ORANGE WHITE 18 RED GRN 98S8S8G8 OHNO SL EELER TAME Slt 18 ORANGE WHITE 18 BROWN WHITE 18 BROWN WHITE 18 LT BLUE aus A CONNECTOR e 10 YELLOW REVERSE PRE CHARGE RESISTOR EES E 10 YELLOW gm FORWARD 18 BLUEWHITE ALIHM 8H 18 BLUWHT 18 YELLOW 18 LT BLUE e 2PIN L CONNECTOR 18 BLUE SONIC K WELD 18 GREEN CURTIS PMC MOTOR 3 PIN 18 GREEN 18 PURPLE 18 YELLOW N3349 11 Bit 18 WHITE BLACK Bes 3 PIN CONNECTOR PIN 14 LT GRE 1HWY78 SL TO CONNECTOR CONTROLLER 10 ORANGE d 6 GREEN 10 BLACK 18 BLACK WHITE 18 LIGHT GREEN 18 RED EN TO MOTOR SPEED SENSOR OUTPUT PIN 15 RED TO HIGH SIDE OF MOTOR SPEED S
89. E SOME WIRING COMPONENTS SHOWN ARE OPTIONAL ACCESSORIES Figure 11 2 Precedent Electric Vehicle Wiring Diagram 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11 3 ELECTRICAL SYSTEM AND TESTING Page 11 4 Ee f USED WHEN THERE ARE LIGHTS BUT NO TURN SIGNAL NORMALLY OPEN MOMENTARY PUSH BUTTON FOR HORN 16 ORANGE H 16 YELLOW SONIC 16 BROWNMWHITE WELD z S ES o E 16 BLUE WHITE 16 WHITE 888600800 KS 16 BLACK DEN CONNECTOR 16 BLACK Wiring Diagrams 16 BLACK 16 ORANGE 16 GREEN 16 BLUE 16 ORANGE 16 RED 16 GREEN 16 GREEN 16 RED 16 RED T URN SIGNAL SWITCH NORMALLY OPEN MOMEN EH PUSH BUTTON FOR HORN 16 BROWN 16 GREY 16 BLUE WHITE 16 WHITE 16 BLUE WHITE 16 WHITE 16 WHITE 16 YELLOW 16 YELLOW 16 GREY BLK 16 BROWNWHITE 16 BROWNWHITE Figure 11 3 Precedent Electric Vehicle Accessory Wiring Diagram USED WHEN THERE ARE TURN SIGNALS 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL SYSTEM AND TESTING HEADLIGHT ASSEMBLY 16 GREEN Wiring Diagrams 16 ORANGE 16 BLACK DC DC CONVERTER 20 AMP FUSE
90. EED PULSES menu item indicates that speed pulses are OFF when the vehicle is in motion or Diagnostic Menu SPEED SENSOR fault code Loose or disconnected motor speed sensor or broken wire Repair and or connect the three pin connector to the motor speed sensor Loose or disconnected 16 pin connector at speed controller or broken wire Repair and or connect the 16 pin connector to the speed controller Failed motor speed sensor Test Procedure 13 Motor Speed Sensor on page 11 34 Test Menu FOOT INPUT menu item indicates that the MCOR internal limit switch is always ON or always OFF Loose or disconnected two pin connector at the MCOR or broken wire Repair and or connect the two 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 to the speed controller Failed MCOR Test Procedure 8 Key Switch and MCOR Limit Switch Circuit on page 11 20 Test Menu FORWARD INPUT and or REVERSE INPUT does not indicate the correct reading or Diagnostic Menu PROC WIRING fault code Loose or disconnected Forward Reverse rocker switch quick disconnect terminals or broken wire Repair and or connect the quick disconnect terminals to the Forward Reverse switch Loose or disconnected Forward Reverse rocker switch three pin connector or broken wire Repair and or connect the three pin conne
91. ELL RIM LOWER TIRE BEADS FLANGE VALVE STEM SIDE UP Figure 8 1 Tire Removal TIRE REPAIR 1 Determine the location and cause of the air leak 1 1 Remove the wheel See Wheel Removal on page 8 1 Inflate the tire to no more than 20 psi 1 38 Bars 1 2 Immerse the tire in water and then mark the point where bubbles are formed by escaping air 1 3 Determine the cause of the air leak See following NOTE Page 8 2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual WHEELS AND TIRES Tires ES NOTE An air leak could be due to a punctured casing faulty valve core improperly seated valve stem or improperly seated tire bead Small holes in the casing can be plugged using a standard automotive tubeless tire repair kit avail able at your local Club Car dealer 2 When the cause of the air leak has been determined remove tire from the rim and repair as required See Tire Removal on page 8 2 TIRE INSTALLATION A WARNING e While mounting or inflating tire keep hands fingers etc from exposed areas between the tire bead and rim 1 Clean both tire beads to remove dirt or other foreign matter 2 Where the tire beads seat clean the wheel rim with a wire brush Wipe away any debris with a clean cloth NOTE Because tubeless tires require a perfect seal in order to seat keeping the tire and rim clean is very important 3 Apply a liberal amount of tire mounting lubricant soap and water solution
92. ENSOR PIN 16 BLUE TO FORWARD amp REVERSE SWITCH REV PIN 13 BLKIWHT TO LOW SIDE OF MOTOR SPEED SENSOR PIN12 BLU WHT TO LOW SIDE OF SOLENOID COIL PIN 11 OPEN PIN 10 TAN TO KEY SWITCH SONIC WELD PIN 9 GRAY AUX 9 1 PIN 8 WHITE TO FORWARD A REVERSE SWITCH FOR PIN 7 ORG WHT TO LOW SIDE OF REVERSE BUZZER PIN 6 GREEN TO ACCELERATOR LIMIT SWITCH L PIN 1 WHTIBLK TO HIGH SIDE OF POTENTIOMETER PIN 2 YELLOW TO SLIDER OF POTENTIOMETER PIN 3 PURPLE TO LOW SIDE OF POTENTIOMETER PIN 4 OPEN PIN LT BLUE POWER DOWN 16 PIN CONNECTOR AT CONTROLLER Figure 11 1 Precedent Electric Vehicle Wiring Diagram 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL SYSTEM AND TESTING Wiring Diagrams 12 BLUE 18 WHITE 16 PINK T TOW SWITCH peren DIODE 16BLUE 16 BLUE e ZE RECEPTACLE ASM 10 BLACK 8 H A oi 18 BROWNWHITE P 7 4 SINGLE POSITION Le GG CONNECTOR 10 RED 18 WHITE TERMINAL 18 BROWNWHITE 10 BLACK 18 YELLOW 6 PIN GROUP 18 LT BLUE CONNECTOR 18 YELLOW 18 RED ON BOARD COMPUTER 18 LT BLUE SPADE TERMINAL 6 BLACK 10 BLACK 6 BLACK NOT
93. Figure 11 8 Activating Coil Test Page 11 16 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL SYSTEM AND TESTING Test Procedures TEST PROCEDURE A MCOR VOLTAGE See General Warnings Section 1 Page 1 1 The accelerator position which is proportional to the MCOR voltage can be displayed with the IQDM hand set If an IQDM handset is not available proceed to MCOR Voltage Test without the IQDM Handset on page 11 17 MCOR Voltage Test with the IQDM Handset 1 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 See WARNING Lift only one end in General Warnings Section 1 Page 1 2 See also following WARNING A WARNING e The key switch should be placed in the OFF position and left in the OFF position for the duration of this test 2 Connect the IQDM to the vehicle as described in the IQDM Owner s Manual 3 Access the Test menu and select THROTTLE by using the SCROLL DISPLAY buttons 4 The IQDM should indicate 0 with the pedal not pressed While monitoring the IQDM display screen slowly press the accelerator pedal As the pedal is pressed the IQDM should indicate a rise from 0 pedal not pressed to 100 pedal fully pressed 5 If the MCOR does not operate as described in step 4 proceed to MCOR Voltage Test without the IQDM Handset on page 11 17
94. Figure 16 5 Page 16 3 See also Figure 16 13 Page 16 8 See following CAUTION CAUTION e Do not reuse bearings after removing them Replace bearings with new ones 6 To disassemble the intermediate gear assembly press off together the bearing 16 and the gear 19 Figure 16 5 Page 16 3 See also Figure 16 13 Page 16 8 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 16 7 TRANSAXLE TYPE G Transaxle Disassembly Inspection and Assembly Transaxle Disassembly and Inspection Section 16 Page 16 8 7 Press the bearing 18 off the intermediate gear assembly Figure 16 5 Page 16 3 Figure 16 13 Intermediate Gear Assembly 8 Disassemble the differential gear case 8 1 Remove the hex bolts 33 and the ring gear 32 from the differential case Figure 16 5 Page 16 3 8 2 Remove the ring gear 8 3 Separate the differential gear case housing If necessary install two of the hex bolts removed pre viously in step 8 1 into the differential gear unit and while holding the unit slightly above the work area lightly tap the bolt heads Figure 16 14 Page 16 8 Remove the two bolts Figure 16 14 Separate Housing 8 4 Remove the differential pin 31 by pushing pin through differential gear case from one side Figure 16 5 Page 16 3 See also Figure 16 15 Page 16 9 8 5 Remove the idler gears and thrust plates 1 and 2 Figure 16 16 Page 16 9 Page 16 8 2005 Pre
95. ION Rack and Pinion RACK AND PINION INSTALLATION 1 To minimize corrosion apply a light coat of anti seize lubricating compound to the splined portion of the steering column universal joint 2 Align the flat portion of the shaft 13 spline with the bolt hole in the upper universal joint and then slide the shaft into the universal joint Install the bolt and tighten to 18 4 ft lb 25 N m Figure 7 3 Page 7 3 3 Simultaneously position 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 80 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 A WARNING e Do not operate vehicle until toe in is adjusted and ball joints are secured 6 Adjust the toe in See Toe in Adjustment on page 7 11 RUBBER MALET 15 16 INCH DEEP WELL Log SOCKET DUST SEAL if Figure 7 11 Install Ball Joint DEEP WELL II TEN Figure 7 12 Rack and Pinion Adjustment Figure 7 13 Rack and Pinion Resistance 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 7 9 STEERING AND FRONT SUSPENSION Front Suspension FRONT SUSPENSION See General Warnings Section 1 Page 1 1 LUBRICATION Two grease fittings are provided one in each spin
96. ITE 16 BLUE 16 GREEN RED 18 BLACK YELLOW 18 BROWN WHITE 18 ORANGE WHITE REVERSE BUZZER S 18 ORANGE 18 BROWN WHITE WARNING LIGHT PROGRAMMER PLUG 18 RED 18 YELLOW 18 GREEN 18 BLACK 8838688888 NOTE SOME WIRING COMPONENTS SHOWN ARE OPTIONAL ACCESSORIES Figure 11 5 Precedent Electric Vehicle Instrument Panel Wiring Diagram Page 11 6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL SYSTEM AND TESTING Troubleshooting General Information Continued e Pedal Up Motor Braking When vehicle speed is above 11 mph 17 7 km h releasing the accelerator pedal will activate motor braking which slows the vehicle speed Once vehicle speed slows to below approximately 11 mph 17 7 km h with the accelerator pedal still released motor braking will be deac tivated and the vehicle will coast freely This feature is selectable Contact your Club Car dealer distrib utor to inquire about this selectable feature Regenerative Braking When motor braking is activated the vehicle motor acts as a generator slow ing the vehicle as it creates energy that is used to charge the batteries Tow Run Switch When the Tow Run switch is in the RUN position the vehicle will function normally When the switch is in the TOW position power to the OBC and co
97. Insert the brushes into the brush rigging as shown Figure 15b 16 Page 15b 12 Insert the two terminal posts through insulators 4 in the end cap 11 wall at the A1 and A2 posi tions Figure 15b 15 Page 15b 10 Place external insulators 5 and washers 6 on each terminal post and secure terminal with nuts 7 Tighten nuts 7 to 100 in lb 11 3 N m Ensure that the terminal posts do not rotate when tight ening the nuts Figure 15b 15 Page 15b 10 Secure the brush rigging to the end cap with two screws Tighten the screws to 25 in lb 2 8 N m Figure 15b 10 Page 15b 6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15b 11 Reconditioning the Motor 15B 15B MOTOR MODEL EJ4 4001 Motor Assembly Motor Assembly Continued Figure 15b 18 Armature Installation Figure 15b 19 Brush Setting 2 5 One at a time push the brushes back until they are completely retracted into their mounting slots and the spring pressure holds them in the retracted position as shown Figure 15b 17 Page 15b 12 3 With the brushes retracted use an arbor press to press the armature shaft into the end cap bearing Figure 15b 18 Page 15b 12 See following CAUTION CAUTION e Make sure the brushes are held back Do not allow the brushes to 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 t
98. MOTOR MODEL EJ4 4001 Motor Component Testing and Inspection e Damaged armature core laminations e Worn burned or glazed commutators e Dirty or oily commutators e Raised commutator bars e Worn armature bearing or shaft A dirty or oily commutator should be cleaned and wiped dry Abnormalities identified during the inspection can help determine original cause of failure Slight roughness of the commutator can be polished smooth with 400 grit or finer sandpaper See following CAUTION and NOTE CAUTION e Do not use emery cloth to polish the commutator Particles of emery are conductive and may short circuit the commutator bars Do not use oil or lubricants on the commutator or brushes NOTE Oil on the commutator may indicate a faulty transaxle input shaft oil seal Armature Ground Test CAUTION e 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 ohms place one probe on the commutator and the other on the armature core The multimeter should indicate no continuity Figure 15b 12 Page 15b 7 If the reading is incor rect replace the armature Figure 15b 12 Armature Test 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15b 7 15B 15B MOTOR MODEL EJ4 4001 Motor Component Testing and Inspection MOTOR FRAME AND FIELD
99. Maintenance and Service Manual BODY AND TRIM Front and Rear Body Repair TYPICAL 4 PLACES 5 PLACES TYPICAL 5 PLACES Figure 4 1 Front Body 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 4 3 BODY AND TRIM Front Body FRONT BODY See General Warnings Section 1 Page 1 1 FRONT BODY REMOVAL 1 Remove the four screws 2 and pull the brow cap 1 from the brow and fascia assembly 4 Figure 4 1 Page 4 3 Pull the front beauty panel 3 up and away from the brow and fascia assembly 4 disengaging the snap tabs 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 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 R Install fascia 6 to brow 5 with five screws 7 Tighten screws to 3 3 ft lb 4 5 N m Figure 4 1 Page 4 3 Install brow and fascia assembly 4 to front underbody with five screws 8 Tighten screws to 1 8 ft lb 2 5 Nem Install front beauty panel 3 over brow 5 Tabs on the forward edge of the front beauty panel should fit into slots between the fascia and the brow Position brow cap 1 to cover the edge of both the brow 5 and the front beauty pane
100. 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 Page 16 6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual TRANSAXLE TYPE G Transaxle Disassembly Inspection and Assembly APPEARANCE OF MOTOR MAY BE DIFFERENT FROM THE MOTOR SHOWN ABOVE Figure 16 12 Motor Positioning Bolt 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 remove the bolts 8 Figure 16 5 Page 16 3 2 Remove 11 bolts 24 that hold housing together 3 Pull the halves of the housing 11 and 20 apart If necessary tap lightly on the spline of the input pinion 17 See following CAUTION CAUTION e To prevent damage to the housing mating seal surfaces use caution when separating halves 4 Remove input pinion gear 17 by pulling gear out while rocking intermediate gear assembly 19 Lift intermediate gear assembly and differential gear case unit out simultaneously Figure 16 5 Page 16 3 See following CAUTION CAUTION e Do not damage gears Use extreme care when handling them 5 Use a bearing puller or arbor press to remove bearings 16 from the input pinion gear If the oil seal 10 is damaged replace it
101. NSION APPEARANCE OF SCORECARD HOLDER MAY BE DIFFERENT THAN THAT SHOWN TYPICAL 2 PLACES 8 NOT REQUIRED FOR SOME SCORECARD HOLDERS e TYPICAL 4 PLACES Figure 7 3 Steering Column 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 7 3 STEERING AND FRONT SUSPENSION Rack and Pinion Steering Column Removal Continued 4 Loosen the bolt 11 that attaches the steering column universal joint to the stud on the steering gear Figure 7 3 Page 7 3 5 Remove the four bolts 10 that attach the steering column to the frame 6 Remove the steering column from the vehicle STEERING COLUMN INSTALLATION 1 For ease of assembly and to prevent corrosion apply a light coat of anti seize or lubricating compound to the splined stud extending from the steering gear Insert the end of the steering column with the universal 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 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 4 ft lb 25 N m Verify bolt 12 torque is 18 4 ft lb 25 N m 5 Install front bumper dash assembly dash insert and instrument panel See Section 4 Body and
102. OMPONENTS 1 Inspect the insulators 4 and 7 for cracks or other damage Figure 15a 10 Page 15a 8 2 Inspect the brushes 13 for damage or excessive wear Replace brushes if required See following NOTE 3 Inspect the brush springs 14 Figure 15a 10 Page 15a 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 15a 8 Page 15a 7 CAUTION e When checking brush spring tension do not over extend the spring Using excessive force will damage the spring NOTE When installing new brushes remove and replace brushes one at a time This method ensures the terminals and brushes will be properly positioned in the rigging Refer to Motor Assembly for brush installation See Motor Assembly on page 15a 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 aclean cloth wipe the carbon dust off of the bearing Inspect the bearing by spinning it by hand and checking for both axial A and radial B play Figure 15a 9 Page 15a 7 2 Replace the bearing if it is noisy does not spin smoothly or has excessive play Check the bearing and replace if rusted worn cracked or if there is an abnormal color change in the metal of the bearing Do not remove the bearing from the armature shaft unless it is to be replaced
103. OTE NOTE If the motor wires were not tagged when disconnected refer to the wiring diagram for proper con nection See Wiring Diagrams Section 11 Page 11 2 7 Insert bolts through the spring shackles and bushings in the leaf spring eyes Secure bolts with lock nuts Tighten to 15 ft lb 20 3 N m 8 Connect the brake cables using new bow tie pins 1 Figure 16 7 Page 16 5 9 Install the shock absorbers Tighten shock absorber retaining nuts until the rubber bushings expand to the same size as the cup washers 10 Install the rear wheels and finger tighten the lug nuts 11 Lift the vehicle and remove the jack stands 12 Lower vehicle and tighten the lug nuts using a crisscross pattern to 55 ft lb 74 6 N m 13 Inspect the vehicle to check for proper operation See following WARNING A WARNING e Make sure that the vehicle operates in the forward direction when the Forward Reverse switch is in the FORWARD position e 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 e Make sure that the vehicle does not operate when the Forward Reverse switch is in the NEUTRAL position 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 16 11 INDEX A accelerator return Spring eeeeeeeeeeeeees 5 4 ACCESS panel cccccee
104. Protector Spray CCI P N 1014305 to minimize corrosion REVERSE BUZZER VIEWED FROM UNDERSIDE OF INSTRUMENT PANEL Figure 12 8 Reverse Buzzer Page 12 8 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL COMPONENTS Electronics Module Cover POWER CONNECTIONS CONNECTOR SCH YELLOW FROM CONTROLLER 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual GRAY WIRE TO CHARGER 0 RECEPTACLE 00 d RN 7 V i Fe We 6 PIN S CONNECTOR a OBC FROM DRIVER SIDE BLACK WIRE TO CONTROLLER Figure 12 9 Electronics Module Removal Page 12 9 ELECTRICAL COMPONENTS Electronics Module Cover ELECTRONICS MODULE See General Warnings Section 1 Page 1 1 While it is not necessary to remove the electronics module from the vehicle access to individual components may be easier with the module removed Electronics Module 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 electronics module cover See Electronics Module Cover Removal on page 12 5 3 Remove three power connection screws on top of the controller 1 and remove the wires from the screw threads Figure 12 9 Page 12 9 Disconnect the 16 pin connector 4 pin connector and the spade connectors from t
105. RONT SUSPENSION Steering Column Steering Wheel Removal Continued 6 6 Remove the steering wheel bolt 6 and the steering wheel 7 from the steering column 9 Figure 7 3 Page 7 3 ot OF SCORECARD HOLDER MAY BE DIFFERENT THAN THAT SHOWN Figure 7 1 Steering Wheel Puller Figure 7 2 Steering Wheel Puller STEERING WHEEL INSTALLATION NOTE To minimize corrosion and to make future removal of the steering wheel easier apply a small amount of oil or anti seize compound to steering shaft before installing the steering wheel 1 Install the steering wheel 7 on the steering column shaft 9 Be sure to align the match marks placed on the wheel and steering column in step 4 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 4 If required install the plate mounting screws 8 Tighten screws to 16 in Ib 1 8 N m STEERING COLUMN See General Warnings Section 1 Page 1 1 STEERING COLUMN REMOVAL 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 2 Remove the steering wheel as previously instructed 3 Remove the dash insert instrument panel dash assembly and front bumper See Section 4 Body and Trim Page 7 2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Steering Column STEERING AND FRONT SUSPE
106. S 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 assembly back and forth on the spindle Movement of the wheel and hub on the spindle indicates that the hub bearing is worn therefore the hub assembly must be replaced See Front Hub Removal on page 7 17 FRONT HUB REMOVAL 1 Remove the front wheels See Wheel Removal Section 8 Page 8 1 Remove dust cap 12 and lock nut 11 Figure 7 19 Page 7 16 Slide the hub assembly 9 off of the spindle shaft 3 Lightly sand spindle shaft to clean away any light rust af ON Inspect the surface of the spindle shaft for surface damage It should be clean and smooth If severe pit ting from rust or corrosion has occurred replace the spindle assembly See Kingpin and Steering Spin dle Removal on page 7 13 HUB INSTALLATION 1 Clean and apply a light coat of anti seize lubricant to the spindle shaft 3 Slide the hub assembly 9 onto the spindle shaft Figure 7 19 Page 7 16 Install a new flanged lock nut 11 and tighten to 36 ft lb 50 N m Rotate the hub The hub should rotate smoothly without binding side play or any indication of rough spots during rotation PON Install the dust cap 12 using a rubbe
107. SSEMBLIES Brake Shoe Installation ON TRAILING Figure 6 11 Apply Grease To Brake Adjuster Figure 6 12 Install Adjuster Wheel Trailing Shoe BRAKE SHOE INSTALLATION See General Warnings Section 1 Page 1 1 See also Warning on Page 6 1 1 Turn the adjusting wheel screw so that the shoe slot is vertical then position the trailing shoe in the slots in the shoe mounting block and adjuster assembly Figure 6 12 Page 6 6 See following NOTE NOTE The trailing shoe has 17T stamped into the tip of the shoe flange Figure 6 12 Page 6 6 The leading shoe is stamped 17L When installing the shoes the stamping on both shoes should be ori ented to the top of the brake assembly When installing the shoes on the passenger side of the vehicle the side of the trailing shoe flange 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 springs onto the trailing shoe already installed Then hold the leading shoe next to the trailing shoe correctly oriented and attach the springs to it Figure 6 14 Page 6 6 BRONZE SPRING SPRING COILS lh ers Es Oyy SILVER SPRING Note that the s
108. Sensor ocarina NENNT Qe A eed lei ana ins Sa SECTION 15B MOTOR MODEL EJ4 4001 General MOrmatio 2225s E EE coax ce does onc Eesen le ege Eu let te BEE Motor Removal E Motor Disassembly Reech ie sans ibd ERR bead Deg andes nese Motor Component Testing and Inspection Armature Inspection and Testing eerie iia esnan a EE REE EA Raa EEA rA NE a N EARRAS Motor Frame and Field Windings Inspection sssssesssssssisssesrrssssrrssstirrssstinrnnsntinnnnsttnnnnntnnnnnnennn Motor Brush Spring and Terminal Insulator Inspection Reconditioning the Motor Motor ASSOMDIY eosi a E E A E EE he yee A Page viii 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Motor Installation gen Eet gge eege Ee ebb eiert eg Mle ies beetle ee h ciel teteateh elec ive atue 15b 13 SECTION 16 TRANSAXLE TYPE G Obert aenn eat ats bee tla tle ele iat ie at te ant eet 16 1 Axle Bearing and Shaft ET 16 1 KEE EE 16 1 Lu WEE 16 4 Transaxle i EENS AEN Sp eh eee de a a Mi ek an oe 16 5 Transaxle E EE 16 5 Transaxle Disassembly Inspection and Assembly AAA 16 7 Transaxle Disassembly and Inspection o eee ceeceeeeeeeeee cette ee eeeeae ee eee eaaaeeeeeeeaaeeeeeeeaeeeeeeeeaeeeeeene 16 7 Re IER ue EE 16 9 Transaxle Installation 77 EEN epee SEENEN EENS eet een 16 10 SECTION i INDEX 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page ix SECTION 1 SAFETY To ensure the safety of those
109. Speed Sensor Test without the IQDM Handset 1 Turn the key switch to the OFF position and place the Forward Reverse switch in the NEUTRAL position 2 With batteries connected disconnect the three pin connector at the motor speed sensor 3 Check voltage at black white wire 3 1 Using a multimeter set to 200 volts DC place the red probe on the battery no 1 positive post and place the black probe on the black white wire terminal socket 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 Check voltage at the red motor speed sensor wire 4 1 With Tow Run switch in the RUN position and using a multimeter set to 20 volts DC place the black probe on the battery no 4 negative post and place red probe on red wire terminal socket in three pin connector The voltage reading should be approximately 15 16 volts 4 2 If the voltage reading is zero volts check the continuity of the red wire from the 16 pin connector at the speed controller to the three pin connector at the motor speed sensor If the wire continuity is correct replace the speed controller 4 3 If the reading is below 14 volts replace the speed controller 4 4 If the vo
110. TEM AND TESTING 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 Troubleshooting NOTE Before troubleshooting the vehicle check the diagnostic history from the Special Diagnostics Menu Note any fault codes TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Test Menu THROTTLE value does not increase as the accelerator pedal is pressed or Diagnostic Menu THROTTLE FAULT 1 fault code Loose or disconnected three pin connector at the MCOR or broken wire Repair and or connect the three pin connector to the MCOR Loose or disconnected 16 pin connector at speed controller or broken wire Repair and or connect the 16 pin connector to the speed controller Failed MCOR Test Procedure 4 MCOR Voltage on page 11 17 Test Menu HEATSINK C indicates that temperature is above 85 C 145 F or Diagnostic Menu THERMAL CUTBACK fault code Over adjusted brakes Section 6 Wheel Brake Assemblies in the appropriate maintenance and service manual Vehicle is over loaded Ensure that vehicle is not over loaded before returning to operation Test Menu ARM PWM value does not reach 100 when vehicle is at full speed Failed MCOR Test Procedure 4 MCOR Voltage on page 11 17 Test Menu SP
111. TIFIER SCR CIRCUIT See General Warnings Section 1 Page 1 1 The silicon controlled rectifier SCR 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 that has the black 10 gauge wire attached to it The reading should be approximately 36 42 volts If the reading is zero volts check the black 10 gauge wire connection to the OBC connector Check the continuity of the black 10 gauge wires If the wires and connections are okay the SCR has failed Replace the OBC If the reading is correct proceed to the following step Plug in AC and DC cords When the battery charger relay clicks on reading should be approximately 48 volts full battery voltage If the reading does not rise from approximately 40 volts to full battery voltage when the DC cord is plugged in and the relay clicks on check the following items e Black wire terminal socket in the charger receptacle Page 11 32 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL SYSTEM AND TESTING Test Procedures e Onboard computer gray wire See Test Procedure 11 Onboard Computer Gra
112. Test eut edd EEN eege Meteo ahaa ete 13 7 On Charge Voltage Test E 13 7 Hydrometer Test 222 ees See 13 7 Discharge Test eege see AR E EA TE E n E ieeedSend EN SAET E A EEN De E ege 13 9 Battery Troubleshooting Examples srice iinseii rerna aeaaea PAA EARE AAEE ENADE EARS a ai 13 11 Battery Storage EE 13 12 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page vii Charging a Battery Pack that has Low Voltage 0 ccececceeeeeeceneeeeeeeeeceaeeeseaeeecaeeeeeaaeseceeeesiaeeneneees SECTION 14 BATTERY CHARGER SECTION 15A MOTOR MODEL 5BC59JBS6365 General MfOrmatiOn ONAE NE geesde eege eege hl Sey Motor Jdentification cr Motor Component Testing and Inspection Armature Field Windings INSPECTION naiseks aeir ei ea eea eiaa AEREE TE Kea CA TAER Motor eu e ELE Bearing lee Le EE Beann Ku EE Bearing Installation 720 eRNEEENEEEE NEEN ZEN Speed Sensor Magnet Inspection cceeceeeeeeeececeeeeeeeeeeeeeeeeseaeeceeeeeesaaeeseeeeeesaeeeseaeeeseeeeseiaeeseaes Speed Sensor Magnet Removal cccecccceecceceeeeeeeeaeeceeeeeeeeaeeeeceeeeseaeeeseaeeesaeeeeeaaeseeeeeessaeeseneees Speed Sensor Magnet Installation cccceeescceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaaeeeeeeeeeaaeeeeeeeeeeaeeeiaeeseeees Reconditioning the Motor cccesccccceceseccceeeeeeeceeeeeeesseaeaeeesecaeeeessaecaeaesecaaeessaeaaeeeeneeaeeeesneeaeenennies let le EE Motor Installation ee ere ee Ee ee Motor Speed
113. WARD there should be continuity If the readings are incorrect replace the switch Place the black probe on the white wire terminal 1 position on the rocker switch and place the red probe on the red wire terminal With the switch in REVERSE there should be continuity If the readings are incorrect replace the switch Page 11 36 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL SYSTEM AND TESTING Test Procedures TEST PROCEDURE 16 REVERSE BUZZER 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 2 2 Remove the instrument panel See step 2 of Key Switch Removal Section 12 Page 12 1 3 Disconnect the orange white and pink wires from the reverse buzzer 4 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m 5 Place the key switch in the OFF position and the Tow Run switch in the RUN position 6 Using a multimeter set to 200 volts DC place the black probe on battery no 4 negative post and place the red probe on the pink wire terminal end that was disconnected from the reverse buzzer The read ing should be approximately 48 volts full battery voltage 6 1 If the voltage reading is correct proceed to step 7 6 2 If reading is zero volts c
114. WINDINGS INSPECTION 1 2 Remove the motor from the vehicle See Motor Removal on page 15b 2 Remove the and cap and armature by performing steps 1 through 7 of Motor Disassembly on page 15b 4 Burned or scorched insulation on the field windings indicates the motor has overheated due to overloads or grounded or shorted coil windings If the insulation on the field windings is scorched replace the motor or the stator shell assembly MOTOR BRUSH SPRING AND TERMINAL INSULATOR INSPECTION Brush Spring Tension Test 1 2 Remove the motor from the vehicle See Motor Removal on page 15b 2 Remove the end cap and armature by performing steps 1 through 7 of Motor Disassembly on page 15b 4 Inspect the brush springs 14 Figure 15b 15 Page 15b 10 Replace springs that are discolored from heat light gold or blue tinted Test the brush springs for proper tension 4 1 Place a C shaped steel plate on a scale 4 2 Place the end of the C shaped plate so that it is between the spring and the brush as shown Figure 15b 13 Page 15b 9 4 3 Gently pull the scale to obtain the spring tension reading See following CAUTION CAUTION e When checking brush spring tension do not over extend the spring Using excessive force will damage the spring 4 4 Replace springs which require a force of less than 35 oz 990 grams Figure 15b 13 Page 15b 9 See following NOTE NOTE When installing new brushes remove and replace brushes
115. Wocl Maintenance 2005 And PRECEDENT Service Ingersoll Rand IQ System Electric Vehicles Manual No 102680401 Edition Code 0205C0306B FOREWORD Club Car vehicles are designed and built to provide the ultimate in performance efficiency however proper maintenance and repair are essential for achieving maximum service life and continued safe and reliable operation This manual provides detailed information for the maintenance and repair of the electric Precedent vehicles and should be thoroughly reviewed prior to servicing the vehicle The procedures provided herein must be properly implemented and the DANGER WARNING and CAUTION statements must be heeded This manual was written for the trained technician who already possesses knowledge and skills in electrical and mechanical repair If the technician does not have such knowledge and skills attempted service or repairs to the vehicle may render the vehicle unsafe For this reason Club Car advises 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 vehicle service seminars periodic service bulletins maintenance and service manuals an
116. a 13 Page 15a 12 Align the match marks on the end shield and the stator shell then install the four screws 8 Figure 15a 10 Page 15a 8 Tighten the screws to 90 in lb 10 N m Make sure the motor speed sensor wires located on the end shield are aligned between the termi nals on the motor housing 4 Make sure the armature turns freely If it does not turn freely disassemble the motor to find the problem Make sure the bearing is properly seated in the end shield when assembling the motor 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15a 11 15A 15A MOTOR MODEL 5BC59JBS6365 Motor Installation Motor Assembly Continued END SHIELD MOUNTING SCREW TERMINAL BEARING RETAINER MOUNTING TAB EN Figure 15a 12 Brush Installation Figure 15a 13 End Shield Installation MOTOR INSTALLATION See General Warnings Section 1 Page 1 1 1 Clean the transaxle input shaft 1 1 Spray the input shaft thoroughly with CRC Brakleen or equivalent brake cleaner degreaser 1 2 Wipe input shaft with a clean cloth 1 3 Inspect the grooves of the input shaft and remove any remaining debris 1 4 Repeat steps 1 1 through 1 3 until input shaft is clean 2 Lubricate the transaxle input shaft 2 1 Squeeze approximately 1 2 inch 1 3 cm of moly teflon lubricant CCI P N 102265201 from tube onto a putty knife as shown Figure 15a 14 Page 15a 13 2 2 Rotate wheels to rotate input
117. aes 4 2 Gouges Punctures Tears Large Scratches and AbraSiOns ccccceccecsseceeeeeesseeeeeesneeeeeseeaaes 4 2 FON BOO xs ssid eects a eadchcs E 4 4 Front Body Removal TT 4 4 Front B dy Installation soruna hei nace ate i ee ea 4 4 FONE Lu 4 4 Instrument Pane h ebe Ee Ee 4 4 Instrument Panel Hemoval zeri wa aeran a eea KAATE A EREE I AES 4 4 Instrument Panel Installation ts iriseora ENAA AEEA A A 4 6 Floor Martand Retainers oora ered iea en ra Ee EAr LRR Eere E Eaa En EEEE ANTER ERKAN RIAA EACEA EEr RRES 4 6 Floor M t Retainer Removal sr sarrr arnan nesen a NEE EA Ee EEE SAART ENNE EEEE TETN RA 4 7 Floor Mat Retainer Installation eseese s a AERES AT AEE EEA EEE R 4 7 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page iii Kick Plate and Charger Receptacle Bezel c ccccceceeeeeeeceeeeeeeeeeeseeeeeeeaaaeseeeeeesaaeeseaeeeseeeeseaeeee Kick Plate and Charger Receptacle Bezel Removal c ccccsceeeeeeeeeeeeeeeeeeeeseaeeeeneeeseneeeseneeeees Kick Plate and Charger Receptacle Bezel Installation 0 ccccceeceeceeeeeeeeeeeeeseceeeeeeeeeseeeeeeeeeees Rear Body Two Passenger Vehicles Universal Accessory MOUNTING 0 eeececeeeeeenne eter eee ee eee eae eee eee DURERE ERARA AEAEE EAA AAEE REEERE NEIRA Backrest and Structural Accessory Module SAM ccccceceeseeeeeeeeeeeeeeeeseceeeeeaeeseeeeeeeaaeeeeneees Rear Body Components Two Passenger cccceeeeeeeeeec
118. al posts A1 and A2 13 to identify their positions in the stator shell then remove the nuts 6 and flat washers 5 Figure 15a 10 Page 15a 8 From the outside push the posts through the stator shell wall into the interior of the stator shell 7 Carefully remove the brush rigging and the terminal posts from the stator shell 8 To remove brush springs 14 from the rigging lift the spring extensions out and over the brush mounts and then slide the springs off their mounting tabs Figure 15a 6 Page 15a 5 Page 15a 4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual MOTOR MODEL 5BC59JBS6365 MATCH MARKS Figure 15a 5 Motor Disassembly MOTOR COMPONENT TESTING AND INSPECTION See General Warnings Section 1 Page 1 1 ARMATURE Visual Inspection Disassemble 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 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Motor Component Testing and Inspection Figure 15a 6 Brush Spring Removal Page 15a 5 15A 15A MOTOR MODEL 5BC59JBS6365 Motor Component Testing and Inspection Visual Inspection Continued A dirty or oily commu
119. all Cycle accelerator pedal Motor Failure See Section 15a Motor Model 5BC59JBS6365 Speed controller failure Replace speed controller See Speed Controller Removal Section 12 Page 12 11 Troubleshooting Guide continued on next page 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11 11 ELECTRICAL SYSTEM AND TESTING Troubleshooting TROUBLESHOOTING GUIDE 2 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Vehicle runs slowly Speed sensor disconnected or failed Test Procedure 13 Motor Speed Sensor on page 11 34 Incorrect speed setting To change the programmed top speed of the vehicle an IQDM P handset must be used Wiring improperly wired Check vehicle wiring See Wiring Diagrams on page 11 2 Batteries Batteries discharged Charge batteries MCOR malfunction Test Procedure 4 MCOR Voltage on page 11 17 Motor loose wires Inspect and tighten all wire connections at the motor Failed motor Replace motor See Motor Removal Section 15a Page 15a 3 Vehicle is over loaded Ensure that vehicle is not over loaded before returning to operation Speed controller failure 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 tire
120. ance to ensure OBC is not in powerdown mode 4 3 Check for weak batteries in CDM 4 4 If reading is still not obtained go to the CDM Troubleshooting Guide on page 11 40 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11 39 ELECTRICAL SYSTEM AND TESTING Using the CDM to Retrieve Data from the Onboard Computer Continued Once a value has been obtained in the display window the CDM may be removed from its receiving position and the data reviewed The CDM will hold the values for F1 F2 F3 and F4 until the CDM is turned OFF or it receives another line of data from the same or another onboard computer Use the following procedure to review the data stored in the CDM NOTE The values of all four functions can be recalled by pressing and releasing the CDM button The value currently displayed will be F1 battery voltage CDM TROUBLESHOOTING GUIDE Use the following chart as a starting point for troubleshooting problems with communication between the CDM and onboard computer Contact your Club Car representative for more comprehensive information Page 11 40 CDM Troubleshooting Guide To view F2 press and hold the button on the CDM When Func 2 appears in the display window release the button The value for F2 will then be displayed To view F3 press and hold the button on the CDM until Func 3 appears in the display window Release the button The value for F3 will be displayed T
121. attery Poison Contains acid Causes severe burns Avoid contact with skin eyes or clothing Antidotes External Flush with water Call a physician immediately Internal Drink large quantities of milk or water Follow with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring GENERAL INFORMATION The batteries supplied with an electric Club Car vehicle are different from those supplied with an automobile The outward appearance of these two batteries is similar but the operating characteristics are very different The Club Car electric vehicle battery is a deep cycle battery and the automotive battery is a starting lighting and ignition SLI battery They should never be substituted for one another BATTERY REPLACEMENT See General Warnings Section 1 Page 1 1 A WARNING To prevent electrolyte leakage from the battery vents batteries must be kept in an upright 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 batteries Battery acid can cause severe personal injury to skin or eyes and can damage clothing 1 Before removing batteries note the
122. away from front canopy supports 7 and 10 and rear supports 3 Remove screws 14 securing front canopy support covers to front body Slide canopy support covers 12 and 13 up front canopy supports 7 and 10 to gain access to bolts 11 om fF oO NV Remove two bolts 11 from each front canopy support 7 and 10 and remove canopy supports from the vehicle 7 Remove two bolts 6 from each rear support 3 and pull rear supports from vehicle Page 4 16 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual BODY AND TRIM Canopy Two Passenger Figure 4 12 Precedent Two Passenger Canopy 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 4 17 BODY AND TRIM Canopy Two Passenger TWO PASSENGER CANOPY INSTALLATION 1 Install the front canopy supports 1 1 Ensure the front supports are properly oriented to the correct side of the vehicle as shown Figure 4 12 Page 4 17 The lower profile of each support follows the profile of the vehicle If the supports are placed on the wrong side of the vehicle they will not follow the vehicle s profile 1 2 Align the holes in the lower portion of each front support 7 and 10 with the corresponding holes in the vehicle Insert two bolts 11 through each front support into the threaded holes in the vehicle The bolts are color coded with gold thread lock Only finger tighten the bolts at this time 1 3 Slide the covers 12
123. bove must be corrected for temperature For each 10 F 5 6 C above 80 F 26 7 C add 0 004 to the reading For each 10 F 5 6 C below 80 F 26 7 C subtract 0 004 from the reading Figure 13 4 VIEW AT EYE LEVEL Hydrometer Interpreting the Results of the Hydrometer Test The approximate state of charge can be determined from the following table SPECIFIC GRAVITY APPROXIMATE TEMPERATURE STATE OF CHARGE CORRECTED 1 250 1 280 100 1 220 1 240 E 1 190 1 210 30 1 160 1 180 SC If the difference between the cells is 0 020 or more the low cell should be suspected It may require a catch up charge or it may be a weak cell When the variations between cells reach 0 050 or more the battery with the low cell should be replaced Page 13 8 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Battery Testing BATTERIES VEHICLE BATTERY ELECTROLYTE CORRECTION CORRECTED SPECIFIC GRAVITY REQUIRED No No ee FACTOR CELL 1 CELL 2 CELL3 CELL4 CELL5 CELL 6 ACTION F 1 275 1 280 1 280 1 275 1 280 1 280 12 1 eae is 0 024 0 024 0 024 0 024 0 024 0 024 0 024 SE I Fully 1 251 1 256 1 256 1 251 1 256 1 256 9 EOF 1 260 1 200 1 270 1 265 1 270 1 260 54 3 10 0 012 0 012 0 012 0 012 0 012 0
124. btain a higher specific gravity Performing the Hydrometer Test 1 Be sure batteries have sufficient electrolyte to cover plates by approximately 1 2 inch 13 mm and are fully charged prior to beginning test If water must be added recharge the batteries before performing the hydrometer test 2 Remove the vent cap Using a battery thermometer CCI P N 1011767 record electrolyte temperature of the no 2 cell 3 Squeeze the rubber bulb of the hydrometer and insert into the cell Slowly release the bulb drawing elec trolyte up into the glass tube of the hydrometer 4 When the float rises off the bottom adjust the electrolyte level so that the float rides free of the bottom but does not strike the top of the glass tube Remove the hydrometer from the cell and release the pres sure from the bulb 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 13 7 BATTERIES Battery Testing Performing the Hydrometer Test Continued 5 Hold the hydrometer vertically ensuring that the float is not touching the sides of the barrel Hold the hydrometer at eye level and read the scale at the level of electrolyte Figure 13 4 Page 13 8 6 Record the reading and return the electrolyte to the cell from which it was taken Replace vent cap 7 Repeat steps 2 through 6 on all cells Hydrometer Calibration Most hydrometers are calibrated to read correctly at 80 F 26 7 C The readings obtained as described a
125. c service and lubrication schedules Both the Periodic Service Schedule and the Periodic Lubrication Schedule must be followed to keep vehicle in optimum operating condition 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 10 1 PERIODIC MAINTENANCE Periodic Service Schedule PERIODIC SERVICE SCHEDULE ELECTRIC VEHICLES REGULAR INTERVAL SERVICE Daily service by owner Batteries Charge batteries after each daily use only A Check electrolyte level Add water if Weenly Service by owner Panone necessary See Section 13 Batteries Monthly service by owner Wash battery tops and clean terminals or trained technician Batteries with baking soda water solution Apply Battery Terminal Protector Spray CCI P N 1014305 to battery terminals Check air pressure and adjust if Tires necessary See Section 2 Vehicle Specifications General vehicle Thoroughly wash vehicle including the underside Semiannual service by trained technician only every 50 hours of operation or 100 rounds of golf Brake system Check brake shoes replace if necessary See Section 6 Wheel Brake Assemblies Lubricate brake system per Lubrication Schedule See Section 6 Wheel Brake Assemblies Check brake cables for damage replace if necessary Electrical wiring and connections Check for tightness and damage replace if necessary Front wheel alignment an
126. cator 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 21 to 23 ft lb 81 N m TRANSAXLE INSTALLATION See General Warnings Section 1 Page 1 1 1 If using a chain hoist raise the vehicle and place transaxle in position on the jack stands If using a floor jack lower the jack stands to their lowest settings and place the transaxle in position on the jack stands 2 Align the center hole in the saddle of the transaxle with the pilot bolt in the leaf spring assembly Page 16 10 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual TRANSAXLE TYPE G Transaxle Installation 3 Install the two U bolts jounce bumper mount if required 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 15a Page 15a 12 or Motor Installation Section 15b Page 15b 13 5 If using a chain hoist lower the vehicle while guiding the leaf springs into the rear spring shackles If using a floor jack raise the differential while guiding the leaf springs into the rear spring shackles Then raise the jack stands to support the transaxle 6 Connect the four motor wires Tighten the retaining nuts to 65 in lb 7 3 N m Use two wrenches to pre vent the posts from turning See following N
127. cedent IQ System Electric Golf Car Maintenance and Service Manual Page 7 11 STEERING AND FRONT SUSPENSION Front Suspension Components Toe in Adjustment Continued 5 Subtract the measurement on the front of the tires from the measurement on the rear of the tires The difference is the toe in Proper toe in is 5 16 inch 7 8 mm 6 If adjustment is necessary proceed as follows 6 1 Loosen the jam nut on each tie rod end 1 Figure 7 17 Page 7 11 6 2 Remove the retaining pin 2 and nut 3 that secure the tie rod to the spindle Raise the male threads out of the spindle 6 3 Rotate tie rod end in or out as required 6 4 Attach male thread to spindle tab and recheck the toe in 6 5 As necessary repeat steps 6 1 through 6 4 6 6 Secure tie rod ends with nuts 3 and tighten to 70 ft lb 95 N m Install retaining pins 2 6 7 Tighten jam nuts Tighten to 26 ft lb 35 N m 6 8 After toe in adjustment is made and with wheels in the straight ahead position 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 Remove the retaining pins 15 and retaining nuts 14 2 3 Lift male thread of tie rod from the hole in the spindle tab 4 Remove the tie rod ends from the s
128. cedent IQ System Electric Golf Car Maintenance and Service Manual TRANSAXLE TYPE G Transaxle Disassembly Inspection and Assembly mm O DIFFERENTIAL E e JE ote 2 DOC PIN ee LEFT DIFFERENTIAL Figure 16 15 Differential Pin Figure 16 16 Left Differential 8 6 Remove the differential 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 16 5 Page 16 3 To remove them press them off See following CAUTION CAUTION e 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 worn gears should be replaced as sets TRANSAXLE ASSEMBLY CAUTION e Do not press against the bearing outer race e The housing and all parts must be wiped clean and dry before reassembly 1 If bearings 13 were removed during disassembly install new bearings using an arbor press Figure 16 5 Page 16 3 2 Assemble the differential gear case 2 1 Install the pin 31 Figure 16 5 Page 16 3 Apply a small amount of oil to all thrust plates and to both ends of the pin 2 2 Install the hex bolts 33 and output gear 32 Tighten bolts to 58 ft lb 78 6 N m 3 Press a new bearing 18 onto the intermediate gear assembly Figure 16 5 Page 16 3 4 Press new bearing 16 onto input pinion gear
129. ceeeeeeteeeeeteeees 4 12 4 16 armature motor see motor armature B erte AE E TEE AEE TTET 4 10 backrest and structural accessory module 4 10 bag rack Installation EE 4 10 IT ue LEE 4 10 basket sweater ccccsssscccsscceeseeeeeseeeeeesess 4 10 batteries uer AER aei 13 1 see also battery charger CA 4 cspvnee et oh ava wea eri eet 13 2 CHANGING EE 13 4 deep discharge cceseeceseeceeeseeeeeeeeereseneeessees 13 5 electrolyte adding water mineral content A 13 4 ET RE 13 3 excessive early discharging ecce 13 5 Tle St rOtAtON 29 13 5 hydrometer calibration eee 13 8 maintenance preventive cceceeeeeeeeeeees 13 2 see also batteries electrolyte replacement cee eeeeeeeeeceeeeeeesedeeeeeseneeeesneres 13 1 seltdiecharoe nisione at 13 3 Gelle EE 13 12 TOSUNG EE 13 7 discharge test iet anaa as 13 9 interpreting test resultS oo eee 13 10 hydrometer test ccccceesceeeeseceeesereeeeseeere 13 7 interpreting results AA 13 8 on charge voltage test n e 13 7 voltage test nnna Ai 11 14 voltage test under Joad 11 20 troubleshooting examples AAA 13 11 Vibration damage ce eeeeeeeseeeeeeneeetenteeeeneeeees 13 4 battery charger 16 hour shut off 2s esssunziee aaa sintee 13 5 AC Service INCOMING cccccesseeeeeeeeeetteeeees 13 5 numbering vehicles and chargers see 13 5 TESNO fs ee ee AE 13 7 on charge voltage test n e 13 7 battery warning light Installation DEE
130. ch to the speed controller The key switch provides a 48 volt signal to the speed controller through pin 10 when the key switch is in the ON posi 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 See WARNING Lift only one end in General Warnings Section 1 Page 1 2 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 10 tan 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 31 CAUTION e Do not fully insert probes into the 16 pin plug Doing so can result in a poor connection Page 11 30 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL SYSTEM AND TESTING Test Procedures SPEED CONTROLLER 200 DCV SETTING READING WITH TOW RUN SWITCH IN RUN AND KEY SWITCH IN THE ON POSITION Figure 11 16 Pin 10 Test 5 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m 6 With th
131. ciccsescccssessccceteteevcceeebes ech eE A E STAS SE E A ERES Rack and Pinion Assembly Rack and Pinion Installation Front Suspension Lubrication Wheel Alignment Front SUSPENSION Components eceeeeeeeeeeeeeeeeeeeeeeeeeaaeeceeeeeecaaeeeeeeeeeesaaeeseeeeeesaeeeseaeeeseaeeeeeeeseaeees Tie Rod End Removal Tie Rod Installation Leaf Spring Removal Leaf Spring Installation Kingpin and Steering Spindle Removal cccccccceceeceeeeeeceeeeeaeeceeeeeesaaeeseeeeescaeesseneeesneeessnaeessaes Kingpin and Steering Spindle Installation ccccceeeeeececeeeeeeeeeeeeeeeeeeaeeceeeeeeeeaeeseeeeeesaeeeeneeeeeaees Control Arm Removal Control Arm Installation Shock Absorber Removal Shock Absorber Installation Front Wheel Bearings and Hubs Front Wheel Free Front Hub Removal Hub Installation SE Le SECTION 8 WHEELS AND TIRES General Information Wees Wheel Removal Wheel Installation 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual 7 1 7 1 7 1 7 2 7 2 7 2 7 4 7 4 7 4 7 5 7 8 7 9 7 10 7 10 7 10 7 12 7 12 7 12 7 13 7 13 7 13 7 13 7 14 7 14 7 14 7 14 7 17 7 17 7 17 7 17 8 1 8 1 8 1 8 1 Page v IIe iere gege Be get neath eh deg beet Feieren Roles als heb Beete EES Steeg 8 2 Dre Hemes ccc es ek SE Wea deed ee a nln eet ine ee ade 8 2 TEROA ai aaa a eebe Eed eebe eeh 8 2 Tare Tristallationt 3 A as a eebe dE
132. ck probe on the S2 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 the vehicle and repaired by a qualified technician See Motor Removal on page 15b 2 MOTOR See General Warnings Section 1 Page 1 1 MOTOR REMOVAL 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 Disconnect wires from the terminals on the motor using two wrenches to prevent posts from turning Label the wires to ensure proper reconnection 3 Slightly loosen all the lug nuts on both rear wheels 4 Place floor jack under transaxle and raise rear of vehicle Figure 15b 1 Page 15b 3 then place jack stands under frame crossmember between the spring mount and the side stringer just forward of each rear wheel Lower the vehicle to let the jack stands support the vehicle Figure 15b 2 Page 15b 3 See following WARNING A WARNING e Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 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 the wheels that remain on the floor When not performing a test or service procedu
133. corner of retainer This screw threads into a J clip 5 that is attached to the rear underbody 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 d Position the retainer on the vehicle and press firmly to engage the trim clips to the vehicle Figure 4 4 Page 4 6 Install one screw 4 at the lower rear of the retainer Tighten screw to 1 8 ft lb 2 5 N m Ensure the floor mat is properly positioned beneath the top flange of the retainer and install two screws 2 Tighten screws to 4 4 ft lb 6 0 N m KICK PLATE AND CHARGER RECEPTACLE BEZEL See General Warnings Section 1 Page 1 1 KICK PLATE AND CHARGER RECEPTACLE BEZEL REMOVAL 1 If charger bezel 4 requires removal use charger bezel tool CCI P N 102562401 to remove bezel from the kick plate Figure 4 5 Page 4 8 Remove floor mat See Floor Mat and Retainers Section 4 Page 4 6 Remove three screws 1 that hold the kick plate 2 to the vehicle 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 Remove kick plate from vehicle KICK PLATE AND CHARGER RECEPTACLE BEZEL INSTALLATION I Position the kick plate 2 on the vehicle and secure with three screws 1 Figure 4 5 Page 4 8 Ensu
134. cted See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 Remove electronics module cover See Electronics Module Cover Removal on page 12 5 Remove 4 wires from solenoid Loosen both solenoid mounting screws 2 Figure 12 10 Page 12 12 Rotate solenoid up in front and slide off of the component mounting plate Solenoid Installation 1 2 3 4 5 Mount solenoid onto component mounting plate with screws 2 Figure 12 10 Page 12 12 Tighten screws 2 to 5 5 ft lb 7 5 N m Connect yellow 4 and red 5 wires Figure 12 9 Page 12 9 Tighten to 72 84 in lb 8 9 5 N m Install electronics module cover See Electronics Module Cover Installation on page 12 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 and coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion Page 12 12 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL COMPONENTS Onboard Computer OBC ONBOARD COMPUTER OBC See General Warnings Section 1 Page 1 1 Testing the Onboard Computer See Section 11 Test Procedure 2 Page 11 15 Test Procedure 10 Page 11 32 and Test Procedure 11 Page 11 33 Onboard Computer Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting
135. ctifier SCR Circuit 11 Onboard Computer Gray Wire 12 Voltage at Charger Receptacle Red Wire Socket 13 Motor Speed Sensor 14 Solenoid Continuity 15 Forward Reverse Rocker Switch 16 Reverse Buzzer 17 Rebooting the Onboard Computer 18 Battery Warning Light TEST PROCEDURE 1 BATTERIES VOLTAGE CHECK See General Warnings Section 1 Page 1 1 Test Procedures 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 2 The battery voltage can be displayed with the IQDM handset If an IQDM handset is not available proceed to Batteries Voltage Check without the IQDM Handset on page 11 15 Batteries Voltage Check with the IQDM Handset Page 11 14 1 Connect the IQDM to the vehicle as described in the IQDM Owner s Manual 2 Access the Test menu and select BATT VOLTAGE by using the SCROLL DISPLAY buttons The IQDM should indicate at least 48 volts with the batteries fully charged If not check for loose battery connec tions or a battery installed in reverse polarity Refer to Section 13 Batteries for further details on battery testing 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL SYSTEM AND TESTING Test Procedures Batter
136. ctor from the Forward Reverse switch to the wire harness Loose or disconnected 16 pin connector at speed controller or broken wire Repair and or connect the 16 pin connector to the speed controller Failed Forward Reverse rocker switch Test Procedure 15 Forward Reverse Rocker Switch on page 11 36 Troubleshooting Guide continued on next page Page 11 8 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL SYSTEM AND TESTING Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION 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 capacitors to discharge See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 Reconnect the batteries and see if the symptom returns Loose broken or disconnected wire s at solenoid or B speed controller terminal Repair and or connect the loose or disconnected wire s Loose or disconnected 16 pin connector at speed controller or broken wire Repair and or connect the 16 pin connector to the speed controller Failed solenoid Replace solenoid See Solenoid Removal Section 12 Page 12 12
137. d other service publications also represent Club Car s continuing commitment to customer support This manual covers all aspects of typical vehicle service unique situations however do sometimes occur when servicing a vehicle If it appears that a service question is not answered in this manual you may write to us at Club Car Inc P O Box 204658 Augusta Georgia 30917 Attention Technical Services or contact a Club Car Technical Service Representative at 706 863 3000 ext 3580 Copyright 2005 Club Car Inc Club Car and PowerDrive are registered trademarks of Club Car Inc This manual effective August 2 2004 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page i A WARNING e Read Section 1 Safety before attempting any service on the vehicle e Before servicing vehicle read complete section s and any referenced information that may be relevant to the service or repair to be performed NOTE This manual represents the most current information at the time of publication Club Car Inc is continually working to further improve 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 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 no
138. d camber Check and adjust as required See Section 7 Steering and Front Suspension Annual service by trained technician only every 100 hours of operation or 200 rounds of golf If batteries are not performing as Batteries expected see See Section 13 Batteries Pedal group Lubricate all rotating joints See Periodic Lubrication Schedule on page 10 3 General Vehicle Check for loose hardware tighten if necessary A WARNING e If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to make necessary repairs could result in fire property damage severe personal injury or death Page 10 2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual PERIODIC MAINTENANCE PERIODIC LUBRICATION SCHEDULE See General Warnings Section 1 Page 1 1 Periodic Lubrication Schedule PERIODIC LUBRICATION SCHEDULE REGULAR INTERVAL SERVICE LUBRICATION RECOMMENDED LUBRICANT or rained technician Charger receptacle Oo WD 40 ever ours o i Sen me gy Danen mte CETS Front suspension two fittings Gy Chassis Lube EP NLGI Grade 2 Annually by trained Check fill transaxle to plug level 22 oz 0 67 liters SAE 30 WT API technician only Class SE SF or SG Oil or higher dE EN Steeg oe EI Performance Dry Multi Use of golf
139. d contacts welded fault code solenoid contacts have failed closed Replace solenoid See Solenoid Removal Section 12 Page 12 12 Diagnostic Menu MAIN DRIVER ON or MAIN DRIVER OFF fault code Speed controller logic malfunction Disconnect the batteries and allow the speed controller capacitors to discharge See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 Reconnect the batteries and see if the symptom returns Failure of the FET that controls the solenoid coil Replace the speed controller See Speed Controller Removal Section 12 Page 12 11 Troubleshooting Guide continued on next page 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11 9 ELECTRICAL SYSTEM AND TESTING Troubleshooting TROUBLESHOOTING GUIDE 1 SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION 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 and or connect the field coil wires Failure of the motor field windings Section 15a Motor Model 5BC59JBS6365 Failure of the FET s that control field current
140. display the data Function codes and corresponding data are as fol lows Page 11 38 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL SYSTEM AND TESTING Communication Display Module CDM F1 Battery voltage This displays the battery pack s current state of charge A reading of less than 48 volts indicates that the batteries need to be charged If a reading of less than 48 volts is obtained immediately after a charge cycle there may be a problem in the charge circuit F2 Energy units removed since last charge cycle If the display reads over 75 the vehicle battery warning light should be illuminated the vehicle batter ies need to be recharged before being used again This data can be used to make sure all vehicles in a fleet receive equal usage on a short term basis F3 Total accumulated energy units removed since initial vehicle start up This information is most useful in making sure that all vehicles in a fleet receive equal usage over long periods of time F4 Last charge termination type 1 incomplete 2 DVDT 4 normal 8 max timer A 1 2 4 or 8 will be displayed 1 Indicates the last charge cycle was incomplete and the batteries were not fully charged Batteries should be charged again at the earliest opportunity 2 Indicates a back up charge program was employed by the OBC to complete the charge cycle A DVDT charge may be displayed the first few tim
141. dle housing Lubricate these fittings at the recommended interval with the proper lubricant See Periodic Lubrication Schedule Section 10 Page 10 3 CAUTION e To ensure proper lubrication raise front of vehicle to lubricate See General Warnings Section 1 Page 1 1 WHEEL ALIGNMENT Wheel alignment is limited to equalizing the camber angle of each front wheel and adjusting toe in of the front wheels NOTE Prior to making any front suspension adjustments inspect components for wear or damage and repair or replace as 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 but 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 but do not remove the hex nut 8 on the adjustment eccentric 7 Figure 7 15 Page 7 11 in the center of the spring See also Figure 7 19 Page 7 16 4 Use a7 mm deep well socket to rotate the eccentric Figure 7 15 Page 7 11 5 After adjusting camber use a crisscross pattern to tighten the four spring retaining bolts 17 Figure 7 19 Page 7 16 to 23 ft lb 81 N m Then roll the vehicle forward one full tire revolution and recheck the camber See also Figure 7 14 Page 7 11 6 Tighten the hex nut 8 on the adju
142. e under load 11 20 8 key SWICK ooo cece ecentee teeter eeeeeeetneeeees 11 20 8 MCOR limit switch ceeeeeeereeeeees 11 20 9 16 PiIN CONNECHON oo eeeeeeeeeeeeeeeeeeeteaes 11 22 Page LA 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual INDEX 10 onboard computer SCR sassen 11 32 11 OBC gray wire and fuse eeeeee 11 33 12 charger receptacle AAA 11 33 13 speed sensor MOtOr cccceeeeeeeeeeeees 11 34 14 solenoid rirni 11 35 15 Forward Reverse rocker switch 11 36 16 reverse buzzer oo eect eeenteeeeeeeereneees 11 37 17 OBC rebooting ccccceeeseeeeeseeeeeeeees 11 37 18 battery warning light AA 11 38 test procedures motor 1 internal short circuits 0 15a 1 15b 1 2 armature circuit Open eee 15a 2 15b 2 3 field circuit open eee eeeeeee 15a 2 15b 2 armature ground test eee 15a 6 15b 7 tie rod and drag link Installation vest S eees eek eae 7 12 FOMOVAls 2 426 ste e gets ail cies 7 10 tire Installation EE 8 3 removal in dromir a eena ak e deen at 8 2 EDU EEE IEEE EEATT 8 2 Tow Run switch AAA 11 7 Installation eni hice 12 6 we EE 12 6 CT EE 11 19 transaxle type g assembly ate eile SE Sa 16 9 axle bearing msiseme ainsi 16 4 axle shaft Ipnetallaton 16 2 IC we EEN 16 1 elle E 16 7 INSPECCION EE 16 7 NC le ME 16 10 lUbriCatiOn sii cinsiieae ieee aie 16
143. e 1 1 A WARNING e See General Warnings Section 1 Page 1 1 GENERAL INFORMATION The rear suspension of the Precedent vehicle is completely independent It consists of two leaf springs con trolled by two shock absorbers mounted between the springs and the vehicle frame SHOCK ABSORBERS See General Warnings Section 1 Page 1 1 SHOCK ABSORBER REMOVAL AND INSPECTION 1 Check shock absorbers 7 for damage or fluid leakage at the point where the shaft enters the shock absorber body Replace damaged or leaking shock absorbers Figure 9 1 Page 9 2 or Figure 9 4 Page 9 5 2 To remove a shock absorber remove the nut 5 cup washer 9 and rubber bushings 10 from the stem at the top of the shock absorber 3 Remove the nut 5 cup washer 9 and rubber bushings 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 to the size of the cup washer LEAF SPRINGS TWO PASSENGER VEHICLES See General Warnings Section 1 Page 1 1 LEAF SPRING REMOVAL TWO PASSENGER VEHICLES 1 Loosen but do not remove lug nuts on tire and wheel assembly on the side from which the spring is to be removed Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack Position jack stands under
144. e 13 3 3 Maintain proper electrolyte level See Electrolyte Level on page 13 3 4 Batteries should be properly charged every day they are used Check the batteries periodically to see that they are in a full state of charge See Battery Charging on page 13 4 5 Keep hold downs tight See Vibration Damage on page 13 4 SELF DISCHARGE Contaminants on dirty batteries can provide a path for a small current draw that can slowly discharge batter ies thus wasting valuable energy To prevent self discharge 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 bat teries keep in a cool place See Battery Storage on page 13 12 ELECTROLYTE LEVEL A CAUTION e Do not allow battery acid from battery caps or hydrometer to drip onto the front or rear body of the vehicle Battery acid will cause permanent damage Wash immediately BATTERY INDICATOR D CAP PLATES ELECTROLYTE LEVEL AT LEAST 1 2 IN 13 mm ABOVE PLATES OR TO LEVEL INDICATOR Figure 13 2 Battery Electrolyte Level Add water only after charging unless the electrolyte is below the level of the plates If the electrolyte level is below the
145. e Tow Run switch in the TOW position the multimeter should indicate zero volts 7 Place the Tow Run switch in the RUN position and the key switch in the ON position 8 With the key switch in the ON position the multimeter should indicate full battery voltage approximately 48 volts With the key switch in the OFF position the reading should be zero volts 9 If any other reading is obtained check the following items Continuity of the wires in the wire harness Tow Run switch for proper operation See Test Procedure 6 Tow Run Switch on page 11 19 Key switch for proper operation See Test Procedure 8 Key Switch and MCOR Limit Switch Cir cuit on page 11 20 Test Procedure 9H Pin 12 See General Warnings Section 1 Page 1 1 Pin 12 in the 16 pin connector provides a connection point 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 Position jack stands under the frame rails just forward of each spring mount See WARNING Lift only one end in General Warnings Section 1 Page 1 2 3 Disconnect the 16 pin connector at the speed controller 4 Place a jumper
146. e black wire from its connector Disconnect the gray wire from the OBC Remove the three screws 1 that secure the charger receptacle 2 to the bucket Charger Receptacle Installation 1 2 Insert the wires through the hole in the bucket Figure 12 11 Page 12 14 Insert receptacle 2 into bucket Install the three screws 1 that secure the receptacle to the bucket Tighten screws to 16 in lb 1 8 N m Connect gray wire to the OBC Make sure boot is properly seated Connect the black wire to the mating connector Make sure connector is fully seated Connect the red wire to the positive post of battery no 1 Install kick plate See Kick Plate and Charger Receptacle Bezel Section 4 Page 4 7 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m and coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion Page 12 14 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual SECTION 13 BATTERIES A DANGER e See General Warnings Section 1 Page 1 1 A WARNING e See General Warnings Section 1 Page 1 1 e Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed area Wear a full face shield and rubber gloves when working on or near batteries e B
147. e body could melt the body or damage the finish MINOR IMPACT DAMAGE DEFORMATIONS Minor impact damage to a Surlyn body can be repaired using a procedure similar to the one used to remove stress lines To remove deformations resulting from minor impact damage de 2 Hold a heat gun 12 inches 30 cm away from the affected area with the gun on its lowest heat setting Periodically remove the heat gun and bend the body using a push block in the opposite direction of the deformation Continue heating and bending the body until the original shape returns Under no circumstance should the gun be held closer than 6 inches 15 cm to the body See preceding CAUTION MINOR SCRATCHES AND SURFACE BLEMISHES For minor scratches or blemishes in the Surlyn body that do not penetrate the finish le Thoroughly clean the affected area using a strong non abrasive detergent and hot water then clean with Ultra Kleen Solvent Cleaner to remove any oil based contaminants Lightly buff imperfection with a clean soft cloth or buff pad Do not use any kind of rubbing abrasive com pound on body assemblies Wax the entire body part to restore luster and weather protection GOUGES PUNCTURES TEARS LARGE SCRATCHES AND ABRASIONS Touch up is not recommended Replace the entire body part or have it repaired by a professional paint and body repair shop with experience repairing Surlyn bodies Page 4 2 2005 Precedent IQ System Electric Golf Car
148. e dust seal Figure 7 6 Page 7 7 7 Remove the large snap ring 4 Figure 7 7 Page 7 7 8 Remove pinion 5 from the housing 17 Figure 7 8 Page 7 7 If removal is difficult install the univer sal joint onto the pinion and place a fork or a large open end wrench under the universal joint Figure 7 8 Page 7 7 Gently pry the pinion from the housing 9 Remove the universal joint from the pinion 5 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 7 5 STEERING AND FRONT SUSPENSION Rack and Pinion Figure 7 5 Steering Gear Page 7 6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual STEERING AND FRONT SUSPENSION Rack and Pinion Rack and Pinion Disassembly Continued 10 If the ball bearing 4 Figure 7 5 Page 7 6 has been damaged remove the C type stop ring 16 Figure 7 7 Page 7 7 and press the bearing off Figure 7 9 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 a PRESS RAM PINION GEAR E d Figure 7 8 Remo
149. e following WARNING A WARNING e Make sure that the vehicle operates in the forward direction when the Forward Reverse switch is in the FORWARD position e 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 e Make sure that the vehicle does not operate when the Forward Reverse switch is in the NEUTRAL position VIEWED FROM DRIVER SIDE Figure 15b 24 Motor Mount 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15b 15 15B 15B SECTION 16 TRANSAXLE TYPE G A DANGER e See General Warnings Section 1 Page 1 1 A WARNING e See General Warnings Section 1 Page 1 1 LUBRICATION 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 16 5 Page 16 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 lubricant When draining the lubricant the upper plug should be removed so the lubricant will drain faster Be sure the drain plug is installed before filling See following NOTE NOTE Recycle or dispose of used oil or lubricant in accordance
150. e wire harness and test the connected components with the appropriate test procedures See Index of Test Procedures on page 11 14 SPEED CONTROLLER 16 PIN CONNECTOR WIRE TEST PROCEDURE Pin 1 White Black 18 gauge Pin 2 Yellow 18 gauge Pin 3 Purple 18 gauge Test Procedure 9A Pins 1 2 and 3 on page 11 23 Pin 4 Open No wire Pin 5 Light Blue 18 gauge Test Procedure 9B Pin 5 on page 11 24 Pin 6 Green 18 gauge Test Procedure 9C Pin 6 on page 11 25 Pin 7 Orange White 18 gauge Test Procedure 9D Pin 7 on page 11 27 Pin 8 White 18 gauge Test Procedure 9E Pins 8 and 16 on page 11 28 Pin 9 Gray 18 gauge Test Procedure 9F Pin 9 on page 11 29 Pin 10 Tan 18 gauge Test Procedure 9G Pin 10 on page 11 30 Pin 11 Open no wire Pin 12 Blue White 18 gauge Test Procedure 9H Pin 12 on page 11 31 Pin 13 Black White 18 gauge Pin 14 Light Green 18 gauge Pin 15 Red 18 gauge Test continuity of each wire and perform Test Procedure 13 Motor Speed Sensor on page 11 34 Pin 16 Blue 18 gauge Test Procedure 9E Pins 8 and 16 on page 11 28 Test Procedure 9A Pins 1 2 and 3 See General Warnings Section 1 Page 1 1 Pins 1 2 and 3 in the 16 pin connector provide a connection point from the MCOR potentiometer to the
151. ea 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 15a 20 Page 15a 16 2 Connect the three pin connector 22 to the vehicle wire harness 3 Place the Tow Run switch in the TOW position and connect the batteries positive cable first Tighten battery terminals to 110 in Ib 12 4 N m and coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15a 15 15A 15A MOTOR MODEL 5BC59JBS6365 Motor Speed Sensor Motor Speed Sensor Installation Continued Figure 15a 20 IQ Motor Speed Sensor Page 15a 16 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual SECTION 15B MOTOR MODEL EJ4 4001 A DANGER e See General Warnings Section 1 Page 1 1 A WARNING e See General Warnings Section 1 Page 1 1 GENERAL INFORMATION The IQ System vehicle is equipped with a 48 volt DC shunt wound reversible traction motor The shunt wound motor is designed for use on IQ System vehicles only Club Car recommends that motors requiring major repair be sent to a qualified motor repair shop however there are many relatively simple tasks that can be performed by a technician with general knowledge and experience in electr
152. eceeeeeeeeeeeaeeeeaaeeseeeeeesaaaeeeeeeeesnaeeeteeeeees Rear Body Four Passenger Vehicles ANERER Seat EE e IT EE FOOL Diech 1 suchen eegend vaccinia dove ain Al a det a la gege dg Rear Body Components Four PaSSe nger cccccceceeeeeeceeeeeeeeeeeeaeeeeaaeeseeaeeesaaaeseeeeeeseaaeeeeeeeess Canopy Two Passenget eist great depeee Shale Savages a taaa ana aaa aa a agate eaaa paaa a a gh andes Two Passenger Canopy Removal ssssseeesseessisssiississsrrssirnnstnnnttnntttunttnnttnntstnntttnsstnnnsnnnnetnnnn nnana Two Passenger Canopy Installation ccccccceeeceeeeneeceeeeeeeaeeeeeeeeeceaeeeseaeeeseaeeeseaaeseceeeesaaeenennees Canopy Four Passenger ccccccceesceceeeeeeeeaeeceeeeeeseaaeecaeesseaaeesaaeeeseaaessaaneeecaaesgeeeeeeeeaeeeseaaaeennees Four Passenger Canopy PHemoval Four Passenger Canopy Installation cccccceeeeeeceeeeeeeeeeeeeceaeeeseeeeeecaaeeeeeeeeesaeeesenaeeseeesenaeessaes SECTION 5 ACCELERATOR AND BRAKE PEDAL GROUP Pe Cali GrOU Py xis edel ggeger Sege ee eege eegen hecastars Meer ddidmrratemenn edie Pedal Group REMOVAL 0 c cccccsecceeceeeseeeeeeeneeeceaeeeceaaesaaeeecaaaesaaneesaaaeseeaaeeseaaessaaaeeseceeeeeaaessaeeeees MGOR WEE Debris helle ageet nl Weave a are ai aie a ee S Brake ett Spring gee E ari thts a eae ee ee deg eet es ee ube te Sa ae SE ue EE Accelerator Return Spring ccesceceeececeenceeeeeeeeceaaeeeeaeeeceaeeseeaaeecgaeeeesaaeeeeeaeeessaaesesaneeesaeesee
153. ectrical system 12 volt 500 cca at 0 F 17 8 C 650 at 32 F 0 C 105 minute reserve capacity and 35 amp charging capacity STEERING SUSPENSION BRAKES Steering Self adjusting rack and pinion Suspension Front and rear tapered mono leaf springs with dual hydraulic shocks e Brakes Dual rear wheel self adjusting brakes with cast iron drums and single brake pedal with automatic release d d park brake BODY CHASSIS Frame Chassis Aluminum and composite Front and rear body Dupont Surlyn Reflections 5 E Body finish High gloss molded in color Tires 18 x 8 5 8 tubeless 4 ply rated KR DIMENSIONS WEIGHT Overall length een et p Overall width Aa om 130 on Overall height with canopy Geom 180 n Overall height at steering wheel in A Wheelbase Gee on fee om Ground clearance arent Gren Front wheel tread Sei SC Vehicle Specifications continued on next page 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 2 1 Two Four N Passenger Passenger SP ECIFICATIO S Electric Electric Vehicle Vehicle Rear wheel tread eam oa an Weight standard electric vehicle with canopy with batteries Gee Gi Gig Vi Weight standard gasoline vehicle with canopy with battery without fuel Forward speed 12 15 mph 19 24 km h Curb clearance circle diameter 628 ony yas anh Standard seating capacity 2 4 LIQUID CAPACITIES 22 oz 22 oz Transaxle 67
154. ed replace the key switch See Key Switch Removal Section 12 Page 12 1 4 6 If the key switch operates as described in the previous steps install the instrument panel in the reverse order of removal and proceed to the following step 5 Test the MCOR limit switch See following NOTE NOTE Make sure that the key switch is operating correctly and that the key switch and instrument panel are properly installed before proceeding 5 1 With batteries connected and using a multimeter set to 200 volts DC place the black probe on the battery no 4 negative post and place the red probe with insulation piercing probe on the green wire close to the two pin connector on the MCOR 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11 21 ELECTRICAL SYSTEM AND TESTING Test Procedures Key Switch and MCOR Limit Switch Circuit Test without the IQDM Handset Continued A WARNING e The Forward Reverse switch must be in the neutral position to avoid personal injury due to contact with rotating wheels 5 2 With Tow Run switch in the RUN position key switch in the ON position and Forward Reverse rocker switch in the NEUTRAL position the voltage reading should be zero volts When the accel erator pedal is pressed the voltage reading should be approximately 48 volts full battery voltage 5 3 If the voltage reading is 48 volts when the accelerator pedal is not pressed replace the MCOR See MCOR Remo
155. ed with self adjusting mechanically expanding shoe drum brakes on each rear wheel BRAKE SHOE REMOVAL See General Warnings Section 1 Page 1 1 See also Warning on Page 6 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 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 See WARNING Lift only one end in General Warnings Section 1 Page 1 2 Gain access to the pedal group by removing the floor mat and access panel See Pedal Group Removal Section 5 Page 5 1 Loosen the two jam nuts 1 and 3 on either side of 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 Loosen turnbuckle 2 to release tension on the equalizer bracket 4 that pulls on the heads of the brake cables Remove the rear wheels and then the brake drums If the brake drums were easily removed proceed to step 8 A CAUTION e Worn or damaged brake drums cannot be machined to refinish them Replace as necessary NOTE When servicing vehicles with severely worn brake shoes and when the drums cannot be removed by normal methods proceed to step 7 to minimize damage to the brake
156. eeecneeeeeeeeeneenenes 3 2 stress lines see repair front and rear body suspension front Camber adjustment A 7 10 components control arm installation 7 14 ETANOA EEE A E E ks 7 14 kingpin and steering spindle Ipsiallatton 7 13 Cu le VUE 7 13 leaf spring installation 7 13 leaf Spring removal ee eeeseteeeeeeeeeeneeeees 7 13 shock absorber installation 7 14 Cu VUE 7 14 tie rod installation 7 12 tie rod end removal aisinn nas koad dia 7 12 wheel bearings and hub IMSPOCUION e a eta raa Ee eu eins 7 17 installation 7 17 EIAN ee EA E Met tt ee 7 17 lege en NEE 7 10 toe in adjustment A 7 11 wheel alignment A 7 10 suspension rear shock absorber inspection and removal eee 9 1 instalation 9 1 suspension rear four passenger leaf spring installation 9 6 Cu E EE 9 4 suspension rear two passenger leaf spring Installation sec wees soni nate pe 9 4 ue EE EE 9 1 sweater basket ccceeceeeceeeeeeeeseeeeeetees 4 10 T test procedures 1 batteries voltage check sssssnsesessseeesn 11 14 2 onboard computer solenoid lockout circuit 11 15 3 solenoid activating coil eee eeeeee 11 16 3 solenoid diode cccccceeceeeeeeeeeteeeeees 11 16 4 MCOR se Sei eh ehh 11 17 5 motor A1 and A2 voltage eeee 11 18 6 Tow Run switch cceeceeeeeeeeeeeeeeeeeeteeeees 11 19 7 battery pack voltag
157. ehicle and debris shield removed remove the accelerator return spring assembly 2 To install accelerator return spring assembly position the accelerator return spring unit in the pedal group with the lower crosspin of the assembly positioned in the pedal group and secure it in place with the clip 1 Figure 5 5 Page 5 6 3 Position upper crosspin in the tab on the pedal group Figure 5 6 Page 5 6 4 Push accelerator pedal forward to compress the springs in the assembly While the springs are com pressed pull pin from both T shaped bars then release the pedal Figure 5 7 Page 5 6 Page 5 4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Pedal Group ES ACCELERATOR AND BRAKE PEDAL GROUP PPOSITE SIDE VIEW S Figure 5 4 Brake Pedal Page 5 5 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ES ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Figure 5 6 Accelerator Spring Upper Crosspin Figure 5 7 Accelerator Spring Pin Removal PEDAL GROUP INSTALLATION 1 Place the MCOR on the pedal group and secure with two screws 1 Figure 5 3 Page 5 3 Tighten screws to 23 in lb 2 6 N m 2 Connect the wire harness 12 to the MCOR 11 Figure 5 2 Page 5 2 NOTE Connectors will only fit together in one orientation 3 Position the pedal group in vehicle and secure with two screws 2 on the driver side and two screws 1 on the passenger side T
158. ehicle does not operate check the OBC activation circuit 6 1 Using a multimeter set to 200 volts DC place the black probe on the battery no 4 negative post and place the red probe with insulation piercing probe on the red 18 gauge wire located on the OBC side of the six pin connector The reading should be approximately 48 volts If the reading is incorrect test the Tow Run switch and connecting wires See Test Procedure 6 Tow Run Switch on page 11 19 6 2 Using a multimeter set to 200 volts DC place the black probe on the battery no 4 negative 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 battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 2 Remove the two small wire terminals from the solenoid 3 Place red probe of the multimeter on the positive solenoid terminal Place the black probe on the other small solenoid terminal A reading of 180 to 190 ohms should be obtained Figure 11 8 Page 11 16 If not replace the solenoid SOLENOID 2k OHM SETTING
159. end that a safety committee be appointed One of the main concerns of this committee should be the safe operation of the golf cars This should include at a minimum Where golf cars should be driven Ensuring that proper warnings of driving hazards are displayed and visible See below for list of signs available from Club Car Service Parts Department Who should and who should not drive golf cars Instructing first time drivers Maintaining golf cars in a safe driving condition How various rules are to be enforced The safety committee should include all these items and such others as the committee feels necessary or appropriate Warning signs available from Club Car are listed below WARNING SIGN CCI P N Sharp Left 9911211 Sharp Right 9921211 Steep Hill 9931211 STORAGE See General Warnings Section 1 Page 1 1 A WARNING e 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 e Do not attempt to charge frozen batteries or batteries with bulged cases Discard the battery Frozen batteries can explode A CAUTION e Batteries in low state of charge will freeze at low temperatures e To avoid exposing electrical components to moisture and subsequent damages do not use any type of pressure washing or steam cleaning equipment to wash the vehicle
160. ent while the charger is plugged into the vehicle charger receptacle 6 stores operating data which can be read by the Communication Display Module CDM See Communication Display Module CDM on page 11 38 TROUBLESHOOTING The following troubleshooting guides will be helpful in identifying operating difficulties should they occur The guides include the symptom probable cause s and suggested checks The procedures used in making these checks can be found in the referenced sections of this maintenance and service manual TROUBLESHOOTING THE VEHICLE WITH THE IQDM Club Car recommends the use of the IQDM handset for troubleshooting vehicles equipped with the IQ elec trical system Troubleshooting Guide 1 is to be used in conjunction with the IQDM handset Refer to the IQDM Owner s Manual for operating instructions See following WARNING A WARNING e The vehicle operator should not monitor the IQDM while the vehicle is in motion A technician can monitor the IQDM while traveling as a passenger in the vehicle Failure to heed this warning could result in severe personal injury or death In the event that the vehicle is not functioning properly after completing Troubleshooting Guide 1 the techni cian should proceed to Troubleshooting Guide 2 If an IQDM handset is unavailable the technician should proceed to Troubleshooting Guide 2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11 7 ELECTRICAL SYS
161. er 8 3 Using a multimeter set for 20k ohms connect the red probe of the multimeter to the yellow wire at the MCOR three pin connector with an insulation piercing probe Connect black probe to the purple wire with an insulation piercing probe 8 4 With the accelerator pedal fully up not pressed the multimeter should read approximately 1k ohms 8 5 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 floor the multimeter should indicate between 5 67k ohms and 7 43k ohms 8 6 Using a multimeter set for 20k ohms connect the red probe of the multimeter to the yellow wire at the MCOR three pin connector with an insulation piercing probe Connect black probe to the white black wire with an insulation piercing probe 8 7 With the accelerator pedal fully up not pressed the multimeter should indicate between 5 67k ohms and 7 43k ohms 8 8 Slowly press the accelerator pedal while monitoring the multimeter The resistance should drop as the pedal is pressed When the pedal is all the way to the floor the multimeter should indicate approximately 1k ohms 8 9 If the MCOR does not operate as described replace the MCOR TEST PROCEDURE 5 AT AND A2 MOTOR VOLTAGE See General Warnings Section 1 Page 1 1 1 Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack Position jac
162. erates 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 e Make sure that the vehicle does not operate when the Forward Reverse switch is in the NEUTRAL position Page 12 10 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL COMPONENTS Solid State Speed Controller 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 18 Speed Controller Removal 1 Disconnect 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 Remove electronics module assembly from the vehicle See Electronics Module Removal on page 12 10 4 Remove the three self tapping screws 1 that hold the controller to the component mounting plate and remove the controller from the vehicle Figure 12 10 Page 12 12 Speed Controller Installation 1 Install the three self tapping screws 1 that hold the controller to the component mounting plate and tighten to 5 5 ft lb 7 5 N m Figure 12 10 Page 12 12 2 Install electronic module assembly in the vehicle See Electronics Module Installation on page 12 10 3 Install electronics module as
163. es a new set of batteries is charged 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 battery indicator which illuminates when CDM batteries are weak and need to be replaced Weak batteries in the CDM may cause the CDM to register inaccurate information or no information USING THE CDM TO RETRIEVE DATA FROM THE ONBOARD COMPUTER 1 Turn the CDM ON 2 Position CDM on seat bottom so it is aligned directly with the battery warning light Ensure CDM infrared LED receiver is pointed at battery warning light and there is a clear path between them See following NOTE NOTE If by positioning CDM on seat bottom the CDM is unable to collect the data stream from the onboard computer hold CDM approximately 6 inches 15 2 cm from battery warning light 3 Wait approximately 30 seconds for a value to appear in the display window 4 lf avalue does not appear in the display window after 30 seconds try adjusting the aim of the CDM and repeating step 3 until a value appears If there is still no reading check for weak batteries in the CDM 4 1 Adjust aim of CDM 4 2 Drive vehicle a short dist
164. estart the charger After 5 minutes use a multimeter to check and record the voltage of the battery set as well as the individual batteries Set the multimeter to 200 volts DC Place the red probe on the positive post of battery no 1 and the black probe on the negative post of battery no 4 Figure 13 1 Page 13 2 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 volts of each other go to the hydrometer test If any battery reads below 14 0 volts and not within 1 0 volts of those batteries above 14 0 volts replace battery If readings are below 14 0 volts but within 1 0 volts of each other the batteries are old Old batteries may have enough capacity left to last several more months Go to hydrom eter test See Battery Troubleshooting Chart on page 13 6 and the examples on the following pages HYDROMETER TEST A hydrometer measures the specific gravity of the battery s electrolyte The higher the specific gravity the higher the state of charge of the batteries A fully charged battery should read between 1 250 and 1 280 at 80 F 26 7 C Never add acid to batteries to o
165. fficult the brake shoes may need to be adjusted vertically in the mounting slots 9 After the drum is installed make sure the axle and drum turn freely and then install the wheel See Wheel Installation Section 8 Page 8 1 10 Adjust brake cable equalizer See Brake Cable Equalizer Adjustment on page 6 9 JAM NUT TURNBUCKLE Figure 6 18 Equalizer Adjustment Page 6 8 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual WHEEL BRAKE ASSEMBLIES Brake Cable Equalizer Adjustment e BRAKE CABLE EQUALIZER ADJUSTMENT See General Warnings Section 1 Page 1 1 See also Warning on Page 6 1 1 After maintenance on the brake system is complete lower the vehicle onto the floor With the brake pedal in the full up or at rest position adjust the turnbuckle until the proper brake tension is achieved The turn buckle is properly adjusted when the distance from the top of the equalizer to the upper flange surface is 2 inches 1 16 inch 51 mm 1 6 mm 2 Ensure that both threaded rods are visible in the witness holes of the turnbuckle before the jam nuts are tightened Figure 6 18 Page 6 8 3 Tighten the rear jam nut first labeled 1 of 2 to 13 ft lb 17 5 N m Figure 6 18 Page 6 8 then tighten the front jam nut to 13 ft lb 17 5 N m See following WARNING For optimal performance drive the vehicle and apply the brakes approximately 20 times to burnish the shoes center the clusters and adjust the brake
166. g AA 11 40 connector 16 pin see test procedures D DANGER GOTINITION Be RE 1 1 debris shields ee NENEdEEENNNENE EENEG 5 3 diode solenoid MOSHING EE 11 16 drive motor see motor E electric motor see motor electrical system AAA 11 1 TESTING CIFCUITS sissie iinei anitis rinnande 11 13 F floor mat and retainers ceeeeeeeees 4 6 floor mat retainer installation cernerent hn ele 4 7 removal ienn aaa e a aa 4 7 foot deck four passenger EE OaE T 4 14 El UE 4 14 Forward Reverse switch installation WEE 12 4 FOMOVAl ege eege EE 12 3 TOSTING WEE 11 36 front body see body front front bumper ENEE 4 4 fuse Sense lead ccccsesessscsteceeeeeeeeeeeess 11 33 H high pedal detect AAA 11 7 l inspection front wheel free play cccccssrcereereerrs 7 17 motor armature ground fest 15a 6 15b 7 armature inspection seee 15a 5 15b 6 Dearing sive lanes 15a 7 15b 9 Prish 2xiaeneiciiek see ate 15b 8 DrUSN eprimg rinore aa inas 15b 8 field windings sessseeessseeeeeeeseeeneene 15a 6 15b 8 motor component sssssssseneseerrirnsserrrrrenene 15a 7 speed sensor magnet 15a 9 15b 9 shock absorber eee 9 1 transaxle type g sessssserreerrrerrrrrrrirrerrnsrrse 16 7 instrument panel TE te WEE 4 6 ue E 4 4 K key switch El ul EEN 12 2 removal 2 ct drained aie eee 12 1 El DEE 11 20 kick later eege dadd eh ea i 4 7 installation cessed geile needs 4 7 removal acute adits wa eae 4 7
167. gs 15 and steel sleeves 14 Replace any that are worn or damaged LEAF SPRING INSTALLATION 1 Install urethane bushings 15 and steel sleeves 14 into leaf spring eyes Figure 7 19 Page 7 16 2 Install leaf spring 13 bottom spring plate 16 and four bolts 17 Using a crisscross pattern sequence tighten bolts to 23 ft lb 31 N m Install spring in kingpins 7 with bolts 8 Tighten to 17 ft lb 23 N m Install the wheels and finger tighten the lug nuts Lower the vehicle and finish tightening lug nuts using a crisscross pattern to 55 ft lb 74 6 N m Si o Ce D 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 retaining pins 15 and nuts 14 then remove tie rod ends 12 from the tabs on the spindles Figure 7 18 Page 7 15 Remove the nut 1 and conical washer 2 from the top of the kingpin 7 Figure 7 19 Page 7 16 Raise the upper clevis from the kingpin Slide the spindle 3 off the kingpin 7 Remove the wave washer 6 and inspect it If the washer is broken or has a wave bottom to wave crest height dimension of less than 0 040 inch 1 mm it must be replaced OT e N Remove bolt 8 from bottom of kingpin 7 and remove kingpin 8 Inspect the kingpin and spindle If either is worn or damaged it must be replaced 9 Inspect the bushings 4 If the bushings are worn
168. h 8 3 SECTION 9 REAR SUSPENSION General ll te e LEET 9 1 SHOCK eu 9 1 Shock Absorber Removal and Inspection ecccccceeeeceeeeeeeeeeeeeeeeeeeeaeeeeeeeeeceaeeeeeaaeseeeeeesaaeeseeaees 9 1 Shock Absorber Installation c cccscceceececeeeececeeeeeeeeaeeceeeeeeesaaeeeeeeeesaaeeegeeeeesaeeeseaeeeseaeeeseaeeeneees 9 1 Leaf Springs Two Passenger Vehicles cceceeceeeeeeeeeeeeeeeeeeeeeeeeeeeaaaeeeeeeeeeceaeeeseaeeseeaeeesaeeseeeee 9 1 Leaf Spring Removal Two Passenger Vehicles cccceeceeeeeeceeeeeeeeaaeeeeeeeeseaaaeseeeeeeeiaeeeeeeeess 9 1 Leaf Spring Installation Two Passenger Vehicles cccccceeseeceeeeeeeeeeeeeeeeeeeaeeseeeeeesaaeeeeeeees 9 4 Leaf Springs Four Passenger Vehicles cccceceeeeeeeeeeeeeeeeee sees eeeeeaeeeeeeeeseaeeeeneeeeseaeeneneeenaees 9 4 Leaf Spring Removal Four Passenger Vehicles ccccccceseeceeeeeeeeneeeeeeeeesaaeeeeeeeeesaaeeeeeeees 9 4 Leaf Spring Installation Four Passenger Vehicles cc ccccceeeeeeeeeeeeeeeeeeeeeeseaeeseneeeseeeeeeneeeee 9 6 SECTION 10 PERIODIC MAINTENANCE General MOrmatiOn AIOE pee Chae eebe elect cle thet all he dees EE 10 1 Periodic Service Schedule oo cece ccccceceeeeeecceececueeeseeeeeaeaueeeseseaueusseeeeaeaaeseeeseeauaeseesesaeaneneeeeees 10 1 Periodic Lubrication SCHEdUIe A eA a a a e aa a a aa a aaia 10 3 SECTION 11 ELECTRICAL SYSTEM AND TESTING ENEE Nutt e NEE 11 1 Wiring BIEL TEE 11 2 T
169. he end of each brush as shown Figure 15b 19 Page 15b 12 5 Align the match marks on the end cap and the motor frame 1 and secure with two bolts 16 Figure 15b 15 Page 15b 10 Tighten bolts to 130 in lb 14 7 N m 6 Install the speed sensor magnet 24 with screw 23 Tighten to 65 in lb 7 3 N m 7 Install the speed sensor 10 with screws 25 Tighten to 25 in lb 2 8 N m 8 Make sure the armature turns freely If it does not turn freely disassemble the motor to find the problem Page 15b 12 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual 15B MOTOR MODEL EJ4 4001 Motor Installation MOTOR INSTALLATION See General Warnings Section 1 Page 1 1 1 Clean the transaxle input shaft 1 1 Spray the input shaft thoroughly with CRC Brakleen or equivalent brake cleaner degreaser 1 2 Wipe input shaft with a clean cloth 1 3 Inspect the grooves of the input shaft and remove any remaining debris 1 4 Repeat steps 1 1 through 1 3 until input shaft is clean 2 Lubricate the transaxle input shaft 2 1 Squeeze approximately 1 2 inch 1 3 cm of moly teflon lubricant CCI P N 102243403 from tube onto a putty knife as shown Figure 15b 20 Page 15b 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
170. he leaf spring Figure 6 21 Page 6 12 Do not remove bolt 2 Remove the mounting tab 3 of the brake cable from the bolt Using brake cable release tool CCI P N 102555501 compress the retaining clips on the end of the cable housing enough to slide the cable end out of the hole in the frame Remove bow tie locking pin 1 and the clevis pin 2 from the brake lever on each wheel and pull the cle vis 3 away from the lever Figure 6 20 Page 6 12 Using brake cable release tool CCI P N 102555501 compress the retaining clips on the end of the cable housing enough to slip the cable end out of the bracket 4 and remove the brake cable from the vehicle 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 6 11 Brake Cable Removal and Installation L e WHEEL BRAKE ASSEMBLIES Brake Cable Removal and Installation AS SEEN FROM DRIVER SIDE OF REAR OF VEHICLE Figure 6 20 Disconnect Cables at Rear Brakes Figure 6 21 Brake Cable Mounting Tab Brake Cable Installation NOTE The driver side and passenger side brake cables are not interchangeable The driver side cable is shorter than the passenger side cable Make sure the correct cable is used on the correct side Be sure to orient the cable so that the clevis end goes to the wheel rather than to the equalizer bracket 1 Insert the end of the new brake cable through the hole in the frame Figure 6 19 Page 6 11 Push on the cable housing so the
171. he 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 bushings 10 from the lower mounting stem of the shock absorber Figure 9 1 Page 9 2 6 Remove the nuts 13 and the U bolt 11 securing the spring to the transaxle Remove the shock mount bracket 15 and the U bolt 7 Remove the bolt 17 and nut 2 attaching the rear of the spring to the shackle 1 8 Remove the nut 2 and bolt 17 attaching the front of the spring to the vehicle frame and remove the spring 9 Inspect the bushings 4 and sleeves 3 in the spring eyes and replace them if they are worn or dam AS SEEN FROM DRIVER SIDE OF I VEHICLE aged REAR OF VEHICLE Figure 9 2 Support Vehicle on Jack Stands Figure 9 3 Disconnect Brake Cable 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 9 3 Ka REAR SUSPENSION Leaf Springs Four Passenger Vehicles LEAF SPRING INSTALLATION TWO PASSENGER VEHICLES 1 To install the springs reverse the removal procedure See following CAUTION A CAUTION e 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
172. he 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 leads to the on 8 board computer OBC 3 and two wires to tow switch Lift the electronics module from the vehicle See following WARNING A WARNING e 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 completely Electronics Module Installation d o ot w Insert the electronics module into the vehicle Ensure the orientation is correct with the computer toward the front the controller toward the rear and both facing the passenger side of the vehicle Complete connections to the computer the controller and the solenoid per the electrical schematics See Wiring Diagrams Section 11 Page 11 2 Tighten bolts on the controller to 9 ft lb 12 2 N m Tighten nuts on the solenoid to 6 4 ft lb 8 7 N mi Install electronic module cover See Electronics Module Cover Installation on page 12 5 Inspect the vehicle for proper operation A WARNING e Make sure that the vehicle operates in the forward direction when the Forward Reverse switch is in the FORWARD position e Make sure that the vehicle op
173. heck pink wire continuity and Tow Run switch See Test Procedure 2 Onboard Computer Solenoid Lockout Circuit on page 11 15 See also Test Procedure 6 Tow Run Switch on page 11 19 6 3 If the continuity readings are not correct repair or replace the pink wire 6 4 If the continuity readings are correct proceed to step 7 7 Place the Forward Reverse switch in REVERSE Using a multimeter set to 200 volts DC place the black probe on the 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 in the orange white wire or the Pin 7 terminal in the 16 Pin connector is not properly seated repair or replace as required 7 4 If the orange white wire continuity and 16 Pin connector are correct and there is no voltage at the orange wire replace the controller TEST PROCEDURE 17 REBOOTING THE ONBOARD COMPUTER See General Warnings Section 1 Page 1 1 It is possible the onboard computer OBC can become locked up causing the OBC solenoid lockout circuit to malfunction If this condition is suspected restart the computer as follows 1 Disconnect the battery cable
174. hicle does not operate Batteries Batteries discharged Charge batteries Batteries Battery connections Check vehicle wiring See Wiring Diagrams on page 11 2 Battery charger is connected to the vehicle Solenoid lockout feature has disabled the vehicle Disconnect the battery charger from the vehicle Onboard computer failure Test Procedure 2 Onboard Computer Solenoid Lockout Circuit on page 11 15 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 20 Failed MCOR Test Procedure 8 Key Switch and MCOR Limit Switch Circuit on page 11 20 See also Test Procedure 4 MCOR Voltage on page 11 17 Forward Reverse rocker switch Test Procedure 15 Forward Reverse Rocker Switch on page 11 36 Solenoid loose wires Test Procedure 3 Solenoid Activating Coil on page 11 16 Solenoid failed coil Test Procedure 3 Solenoid Activating Coil on page 11 16 Speed controller thermal cutback Allow controller to cool and ensure that vehicle is not over loaded before returning to operation 16 pin connector at speed controller Check for loose or disconnected wires at the 16 pin connector See also Test Procedure 9 16 Pin Connector on page 11 22 High pedal detect Cycle accelerator pedal Motor st
175. his prevents the vehicle from rolling away uncontrolled should the driver park on a slope and leave the vehicle without locking the park brake The vehicle will roll at about 1 mph 1 6 km h If the zero speed detect function remains engaged for two seconds or more a warning buzzer will sound to alert the driver that motor braking has been activated A WARNING e Zero Speed Detect will not limit vehicle speed to 1 mph 1 6 km h on very steep grades Do not operate vehicle on slopes exceeding 20 grades e Pedal Down Motor Braking This feature helps to control vehicle downhill speed Motor braking is activated when the vehicle reaches the programmed top speed and holds the vehicle at that speed Motor braking is automatically disengaged when vehicle speed slows below the programmed top speed continued on page 11 7 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11 1 11 ELECTRICAL SYSTEM AND TESTING WIRING DIAGRAMS CONNECTS TO 12 POSITION CONNECTOR FOR DC DC CONVERTER OR LIGHTS SEE FIGURES 11 3 and 11 4 CONNECTS TO 9 POSITION CONNECTOR FOR CONTROLS INIP SEE FIGURE 11 5 Page 11 2 16 WHITE 16 BLK WHT 16 BROWN 18 BLK D LEFT Wiring Diagrams SPADE Ba 10 AMP FUSE 12 BLUE 12 BLUE 18 BAN e TAILLIGHT 16 BLACK WHITE 16 BROWN 16 YELLOW 16 BLKWHT 16 BROWN e BRED 18 BLK am RIGHT NS TAILLIGHT 12
176. ic motor repair MOTOR IDENTIFICATION There are two types of motors used in 2005 model year IQ System electric vehicles Model 5BC59JBS6365 gray housing and EJ4 4001 black housing Do not attempt to service a motor that has not been properly identified If the motor cannot be properly identified contact your local Club Car dealer or distributor EXTERNAL MOTOR 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 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 2 2 Disconnect wires from terminals on motor using two wrenches to prevent posts from turning 3 With a multimeter set to 200 ohms place black probe on motor housing Scratch through paint to ensure a good connection Place red probe on A1 A2 S1 and S2 terminals respectively Multimeter should indicate no continuity between the motor housing and all individual terminals If readings are incorrect motor will need to be removed from the vehicle and repaired by a qualified technician See Motor Removal on page 15b 2 3 1 An incorrect reading from the A1 or A2 terminal indicates three possible problems a grounded A1 or A2 terminal a grounded wire in the
177. icle Figure 4 9 Page 4 13 4 Remove the four bolts 2 securing the foot deck 1 to the vehicle frame Figure 4 10 Page 4 14 Foot Deck Installation 1 Install foot rest in reverse order of removal 2 Tighten bolts 2 to 71 in lb 8 N m Figure 4 10 Page 4 14 Page 4 14 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual BODY AND TRIM Rear Body Four Passenger Vehicles TYPICAL 2 PLACES TYPICAL 2 PLACES A O ATT Uf Y ri TYPICAL 2 PLACES Figure 4 11 Seats Four Passenger Vehicles REAR BODY COMPONENTS FOUR PASSENGER Rear Beauty Panel Removal 1 Remove seat support See Seat Support Removal on page 4 13 2 Remove four screws 13 attaching the rear beauty panel 12 to the fuel bucket Figure 4 8 Page 4 11 3 Remove two screws 14 and remove the Forward Reverse switch housing 15 from vehicle 4 5 Disconnect electrical wires from the Forward Reverse switch 16 Lift rear beauty panel from vehicle 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 4 15 BODY AND TRIM Canopy Two Passenger Rear Beauty Panel Installation 1 Install rear beauty panel 12 on vehicle Make sure body clips on the rear of the beauty panel engage the mating slot in the rear underbody Secure beauty panel in place with four screws 13 Tighten screws to 3 7 ft lb 5 N m Figure 4 8 Page 4 11 2 Connect the three wires to the Forward Re
178. ies Voltage Check without the IQDM Handset 1 With batteries connected and using a multimeter set to 200 volts DC place red probe on the positive post of battery no 1 and the black probe on the negative post of battery no 4 Figure 11 7 Page 11 15 The multimeter should indicate at least 48 volts with the batteries fully charged If not check for loose battery connections or a battery installed in reverse polarity Refer to Section 13 Batteries for further details on battery testing 200 DCV SETTING Figure 11 7 Battery Test TEST PROCEDURE 2 ONBOARD COMPUTER SOLENOID LOCKOUT CIRCUIT See General Warnings Section 1 Page 1 1 The solenoid lockout circuit disables the vehicle when the battery charger is plugged into the vehicle Use the following procedure to test the solenoid lockout circuit 1 With batteries connected place the Tow Run switch in the RUN position 2 Using a multimeter set to 200 volts DC place black probe on battery no 4 negative post and red probe with insulation piercing probe on the light blue onboard computer wire at a point between the OBC and the six pin connector The reading should be approximately 48 50 volts full battery voltage If the reading is not 48 50 volts proceed to step 3 If the reading is 48 50 volts proceed to Test Procedure 3 Solenoid Activating Coil on page 11 16 3 Place insulation piercing probe on the light blue 18 gauge wire at
179. ighten 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 tension See Brake Cable Equalizer Adjustment Section 6 Page 6 9 6 Place floor cover plate 7 over the floor opening Figure 5 2 Page 5 2 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 5 6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual SECTION 6 WHEEL BRAKE ASSEMBLIES A DANGER e See General Warnings Section 1 Page 1 1 A WARNING e See General Warnings Section 1 Page 1 1 e Some aftermarket brake shoes contain asbestos fiber and asbestos dust is created when these brake mechanisms are handled Wear approved eye and respiratory protection when disassembling and cleaning brake mechanisms Inhalation of asbestos could result in severe personal injury or death Do not use compressed air or aerosol sprays to clean the brake mechanism Clean brake mechanism using the negative pressure enclosure hepa vacuum system or low pressure wet cleaning method per OSHA 29 CFR 1910 1001 GENERAL INFORMATION Precedent Golf Cars are equipp
180. ilver spring is mounted with the coils to the side of the adjustment lever spring A Figure 6 13 Install Trailing Shoe Retainer Clip Figure 6 14 Attach Springs Page 6 6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual WHEEL BRAKE ASSEMBLIES Brake Shoe Installation L 4 While maintaining spring attachment on both shoes position tips of leading shoe in the mounting slots and then push shoe into place Hold shoe in position and install retaining clip Figure 6 15 Page 6 7 5 After the shoes are installed move them together up and down and side to side to make sure that they will easily slide approximately 1 4 to 3 8 inch 6 3 to 9 5 mm without binding Figure 6 16 Page 6 7 LEADING SHOE TRAILING er Figure 6 15 Install Leading Shoe Figure 6 16 Check Shoe Positions 6 Place a flatoblade screwdriver under the adjusting arm and raise the arm off of the adjusting wheel While holding the arm up turn the wheel upward until it stops Figure 6 17 Page 6 7 Remove the screw driver _ ADJUSTING ADJUSTING WHEEL Figure 6 17 Set Adjusting Wheel 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 tran saxle 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
181. inal Protector Spray CCI P N 1014305 to minimize corrosion Figure 12 3 Battery Warning Light FORWARD REVERSE ROCKER SWITCH See General Warnings Section 1 Page 1 1 Testing the Forward Reverse Rocker Switch See Test Procedure 15 Section 11 Page 11 36 Forward Reverse Rocker Switch Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 12 3 ELECTRICAL COMPONENTS Forward Reverse Rocker Switch 2 Remove two screws 2 that hold Forward Reverse rocker switch housing 1 to the vehicle Figure 12 4 Page 12 4 3 Remove the three wires from the rocker switch 4 Press in on the locking tabs on each side of switch 3 and push switch out of housing Figure 12 4 Forward Reverse Rocker Switch 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 and install the two screws 2 Tighten to 20 in lb 2 3 N m 4 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten bat
182. ischarge times at various temperatures of a set of bat teries that delivers 62 minutes at 80 F 26 7 C ELECTROLYTE DISCHARGE TIME TO ELECTROLYTE DISCHARGE TIME TO TEMPERATURE SHUT OFF POINT TEMPERATURE SHUT OFF POINT pee 40 Minutes e n 64 Minutes e ei 45 Minutes ker e 66 Minutes ies 50 Minutes crs 68 Minutes ee 6 54 Minutes aun 70 Minutes Se Sr 57 Minutes esa 72 Minutes BRE 60 Minutes 130 160 F 74 Minutes SE e 62 Minutes DE DE Page 13 10 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Battery Testing BATTERIES BATTERY TROUBLESHOOTING EXAMPLES The following information represents a few examples of troubleshooting battery problems Example 1 Vehicle no 68 was suspected of having a bad battery due to its performance As a result the battery charger test was performed After a full charge the battery charger ammeter read 8 0 amps Next the on charge volt age test was performed and the following results were recorded BATTERY NO 1 2 3 4 On Charge Voltage 15 22 V 15 90 V 14 70 V 15 24 V Battery no 3 appears suspect Battery nos 1 and 4 are also suspect Next a hydrometer test should be con ducted on all batteries Hydrometer test results BATTERY NUMBER CELL NUMBER 1 2 3 4 Cell 1 Positive Post 1 200 1 265 1 300 1 250 Cell 2 1 285 1 275 1 290 1 270 Cell 3 1 265
183. ith Surlyn front and rear bodies Use only commercially avail able automotive cleaners with a sponge or soft cloth for normal cleaning A garden hose at normal residential water pressure is adequate Club Car does not recommend any type of pressure washing or steam cleaning Such a process especially if the vehicle has a Surlyn rear body that is removed will expose electrical components to moisture Moisture entering electrical 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 See following CAUTION and NOTE CAUTION e Use of leveling or rubbing compounds will permanently dull finish of vehicle e Do not apply wax products to the black plastic material of the front and rear underbody the front bumper or the textured area of the rear beauty panel marked NO STEP Wax will cause these surfaces to become discolored NOTE Dispose of waste water properly SEAT To preserve seat appearance clean regularly with mild soap or detergent applied with a sponge or soft cloth Use a soft bristle brush to clean areas that are especially soiled Use the following guidelines Light Soiling A solution of 10 liquid dish soap and warm water applied with a soft damp cloth is rec
184. itioning 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 25 ft lb 84 N m 3 Tighten nuts 2 on spring mounting bolts 17 to 15 ft lb 20 3 N m Figure 9 4 Page 9 5 Page 9 6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual SECTION 10 PERIODIC MAINTENANCE A DANGER e See General Warnings Section 1 Page 1 1 A WARNING e See General Warnings Section 1 Page 1 1 GENERAL INFORMATION To ensure trouble free vehicle performance it is very important to follow an established preventive mainte nance program Regular and consistent vehicle maintenance can prevent vehicle downtime and expensive repairs that can result from neglect Any vehicle not functioning correctly should be removed from use until it is properly repaired This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions Contact your local Club Car distributor dealer to perform all repairs and semiannual and annual periodic service PERIODIC SERVICE SCHEDULE A WARNING e Service repairs and adjustments must be made per instructions in the appropriate section of this manual NOTE If the vehicle is constantly subjected to heavy use or severe operating conditions the preventive maintenance procedure should be performed more often than recommended in the periodi
185. k You Club Car Technical Publication Department 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual NOTES NOTES Club Car f Club Car Inc P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Intl 1 706 863 3000 Fax 1 706 863 5808
186. k stands under the frame rails just forward of each spring mount See WARNING Lift only one end in General Warnings Section 1 Page 1 2 See also following WARNING A WARNING e Keep people and equipment clear from rotating rear wheels Do not allow persons under the car Contact with rotating rear wheels could result in serious personal injury 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 red probe to the A1 green wire motor terminal 3 With Tow Run switch in the RUN position place the Forward Reverse switch in the FORWARD position turn key switch to the ON position and slowly press accelerator pedal 4 Asthe accelerator pedal is pressed the voltage reading should increase from approximately 5 volts RMS when the MCOR limit switch closes to approximately 48 volts RMS with the accelerator pedal fully pressed Page 11 18 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL SYSTEM AND TESTING Test Procedures 4 1 If there is no voltage reading check the MCOR See Test Procedure 4 MCOR Voltage on page 11 17 Also check the continuity of the large posts of the solenoid See Test Procedure 14 Solenoid Continuity on page 11 35 4 2 Disconnect the battery cables as instructed See WARNING To avoid unintentionally start ing in General Warnings Section 1 Page 1 1
187. king 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 Remove the nut 5 cup washer 9 and rubber bushings 10 from the lower mounting stem of the shock absorber Figure 9 4 Page 9 5 Remove the nuts 13 and the U bolt 11 securing the spring and jounce bumper to the transaxle Remove the shock mount bracket 15 jounce bumper bracket 20 and the U bolt 11 Remove the bolt 17 and nut 2 attaching the rear of the spring to the shackle 1 Remove the nut 2 and bolt 17 attaching the front of the spring to the vehicle frame and remove the spring Inspect the bushings 4 and sleeves 3 in the spring eyes and replace them if they are worn or dam aged Page 9 4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual REAR SUSPENSION Leaf Springs Four Passenger Vehicles RER S BRAKE CABLE HANGER MOUNTING ZZ ON EACH SIDE OF VEHICLE TYPICAL 2 PLACES Figure 9 4 Rear Suspension Assembly and Mounting Four Passenger Vehicles 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 9 5 Ka REAR SUSPENSION Leaf Springs Four Passenger Vehicles LEAF SPRING INSTALLATION FOUR PASSENGER VEHICLES 1 To install the springs reverse the removal procedure See following CAUTION A CAUTION e When pos
188. l 3 Secure 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 attaching brackets always insert the bolts 4 through the bottom The nuts are tightened to 13 3 ft lb 18 N m INSTRUMENT PANEL See General Warnings Section 1 Page 1 1 INSTRUMENT PANEL REMOVAL 1 Remove two screws 5 at sides and one screw 4 on top of instrument panel 3 Figure 4 3 Page 4 5 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 Remove two barrel fasteners 7 to release dash tray 6 Remove three screws 2 and remove dash assembly 1 from vehicle Page 4 4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual BODY AND TRIM Instrument Panel Wal N l TYPICAL 2 PLACES TYPICAL 3 PLACES Ke TYPICAL 2 PLACES Figure 4 3 Instrument Panel 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 4 5 BODY AND TRIM Floor Mat and Retainers INSTRUMENT PANEL INSTALLATION 1 Position
189. lb 7 3 N m Secure the white orange green and blue wires with a wire tie so that none of the motor wires will scrub the motor or transaxle when the vehicle is in operation Connect the three pin speed sensor wire to the vehicle wire harness 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual MOTOR MODEL EJ4 4001 Motor Installation 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 bolts to 23 ft lb 81 N m See Section 9 Rear Suspension in the appropriate maintenance and service manual 7 Install the shock absorbers Tighten nut until rubber bushing expands to the diameter of the cup washer 8 If removed install wheels and finger tighten the lug nuts 9 Lift vehicle and remove jack stands Lower vehicle to the floor and tighten 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 Ib 12 4 N m and coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 11 Place the Tow Run switch in the RUN position 12 Inspect the vehicle for proper operation Se
190. le and equipment clear from rotating rear wheels Do not allow persons under the car Contact with rotating rear wheels could result in serious personal injury 7 Place the Tow Run switch in the RUN position turn the key switch to the ON position place the Forward Reverse rocker switch in the FORWARD position and press the accelerator pedal The solenoid should click and the multimeter should indicate continuity If the reading is no continuity replace the solenoid 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11 35 ELECTRICAL SYSTEM AND TESTING Test Procedures TEST PROCEDURE 15 FORWARD REVERSE ROCKER SWITCH See General Warnings Section 1 Page 1 1 Forward Reverse Rocker Switch Test with the IQDM Handset 1 2 Turn the key switch to the OFF position and place the Forward Reverse switch in the NEUTRAL position Connect the IQDM to the vehicle as described in the QDM Owner s Manual Test FORWARD INPUT 3 1 Access the Test menu and select FORWARD INPUT by using the SCROLL DISPLAY buttons The IQDM should indicate OFF when the Forward Reverse switch is in the NEUTRAL or REVERSE position 3 2 Place the Forward Reverse switch in the FORWARD position The IQDM should indicate that FOR WARD INPUT is ON If the IQDM indicates any other reading check vehicle wiring See Wiring Diagrams on page 11 2 Also check the 16 pin connector at the speed controller See Test Pro cedure 9 16 Pin Co
191. lectric Golf Car Maintenance and Service Manual Page 15b 3 15B MOTOR MODEL EJ4 4001 Motor Figure 15b 4 Speed Sensor Magnet Figure 15b 5 End Cap MOTOR DISASSEMBLY 1 Before beginning disassembly place match marks on the motor end cap and motor frame 2 Remove speed sensor and magnet 2 1 Remove the two screws 25 that secure the speed sensor 10 to the end cap 11 Figure 15b 15 Page 15b 10 2 2 Remove the screw securing the magnet to the armature shaft Figure 15b 4 Page 15b 4 2 3 Inspect the speed sensor magnet See Speed Sensor Magnet Inspection on page 15b 9 3 Loosen but do not remove the two screws securing the end cap to the motor frame Figure 15b 5 Page 15b 4 Figure 15b 6 End Cap Disengagement Figure 15b 7 End Cap Removal 4 Orient the motor so that the splined end of the armature is facing down 5 Inspect the area where the end cap mates with the motor frame If the end cap appears to be 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 between the end cap and the head of the bolt place a socket on the head of the bolt See following CAUTION Page 15b 4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual MOTOR MODEL EJ4 4001 Motor CAUTION e Ensure that there is sufficient thread engagement of the end cap bolts
192. ltage reading is correct proceed to the following step Check voltage at the light green wire 5 1 Using a multimeter set to 20 volts DC place the black probe on the battery no 4 negative post and place the red probe on the light green wire female terminal in the three pin connector at the motor speed sensor The voltage reading should be from 4 60 to 4 90 volts 5 2 If the voltage is zero volts check the continuity of the light green 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 5 3 If reading is below 3 50 volts check the continuity of the wires and plug and replace the speed con troller if necessary Page 11 34 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL SYSTEM AND TESTING Test Procedures 6 Reconnect the three pin connector at the motor speed sensor Using a multimeter set to 20 volts DC place the black probe on the battery no 4 negative post and place the red probe with insulation piercing probe on the green wire between the three pin connector and the motor speed sensor 6 1 Raise one rear wheel off ground Slowly turn the rear wheel to rotate the motor armature As the armature rotates the voltage reading should alternate from zero to approximately 4 85 volts The voltage reading will fluctuate from zero to 4 85 volts and back to zero four ti
193. mes for each revolution of the motor armature NOTE The voltage reading of 4 85 is an approximate reading The actual reading may vary from 4 50 to 5 00 volts 6 2 Replace the speed sensor if e There is no voltage reading e The voltage reading is not above 3 50 e The voltage reading does not fluctuate as the motor is turned TEST PROCEDURE 14 SOLENOID CONTINUITY See General Warnings Section 1 Page 1 1 1 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 See WARNING Lift only one end in General Warnings Section 1 Page 1 2 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 ohms place the black probe on one solenoid large post and place the red probe on the other large post The reading should be no continuity 5 Connect the three wires crimped together to the forward large solenoid post Install washer and nut on large solenoid post and tighten to 77 in lb 8 7 N m 6 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 A WARNING e Keep peop
194. n 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 6 Install the electronics module cover See Electronics Module Cover Installation on page 12 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 and coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion Figure 12 6 Tow Run Switch Page 12 6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL COMPONENTS Electronics Module Cover MOTOR CONTROLLER OUTPUT REGULATOR MCOR See General Warnings Section 1 Page 1 1 Testing the MCOR See Section 11 Test Procedure 4 Page 11 17 and Test Procedure 8 Page 11 20 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 7 Motor Controller Output Regulator MCOR Installation 1 Secure the MCOR 2 to the pedal group with two hex head screws 3 Figure 12 7 Page 12 7 Tighten screws to 23 in lb 2 6 N m 2 Connect the two pin a
195. n the discharge machine on and record the voltage reading of battery pack while under load A fully charged set of batteries in good condition should read between 46 49 volts while under load A reading of 32 46 volts indicates discharged or failed batteries Each battery should be checked with a multimeter while under load A reading of 32 volts or less will not activate discharge machine If the voltage of the batteries is below 32 volts the batteries are deeply discharged or have failed Recording the battery pack voltage reading while under load provides a more accurate diagnosis of the condition of the batteries When the discharge machine is ON it places the battery pack under load and many times can help determine if one or more batteries in the set have failed Testing battery voltage while the batteries are not under load will not always indicate the true condition of the batteries For more information about the batteries refer to Section 13 Batteries TEST PROCEDURE 8 KEY SWITCH AND MCOR LIMIT SWITCH CIRCUIT See General Warnings Section 1 Page 1 1 Key Switch and MCOR Limit Switch Circuit Test with the IQDM Handset 1 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 See WARNING Lift only one end in General Warnings Section 1 Page 1 2 Turn the key switch to the OFF position and place
196. nd three pin connectors 1 from the wire harness to the MCOR 3 Install the pedal group See Pedal Group Installation Section 5 Page 5 6 4 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m and coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 12 7 ELECTRICAL COMPONENTS Electronics Module Cover REVERSE BUZZER See General Warnings Section 1 Page 1 1 Testing the Reverse Buzzer See Test Procedure 16 Section 11 Page 11 37 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 two screws from the reverse buzzer Remove the reverse buzzer from the dash panel Reverse Buzzer Installation 1 Install the reverse buzzer in the reverse order of removal Pink wire must be connected to the positive terminal Tighten screws to 4 in lb 0 45 N m 2 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m and coat terminals with Battery Terminal
197. neessaes Pedal Group Installation 0 ccccceeeeceeeeeeeeeeeeeeceeeeeeeeee seas eeeeaaeseceeeeeeaaeeeeeeeeseaaeeseaaeeseeeeeeaaeeeeeeee SECTION 6 WHEEL BRAKE ASSEMBLIES Generalinio matom EE Brak Shoe Removal esrar sraa EA ATES EEST AEN EE SEE AEE ENEAN EATA ARRES Brake Assembly Eleaptgegd a Aiki Bante inh ata A Ai ee ad Brake Shoe Installation cisescscecgsentteccscdsaveceaceutsteccdgubats SE EEAS ETE EANA AAFAA E EEEE TARARE TEE cavecdsesthaceles Brake Cable Equalizer Adjustment ceccceeceeeceeeeeeeeeeeeeeeeee sean eeeeaeesecaeeeeaaaeseceeesaaeeeeaeeeseaeeeseaaeeeed Brake Cluster Removal and Installation ccccccccceccessssceeeceeeeeeeeeesneceeeeseceeeeeeeseeeseeesseseeaeesesseaaeess Brake Cluster Installation reriiseii a a ian O EE tes he ab NE SAREA ARRENE Brake Cable Removal and Installation ccccccc ec cccccceccceceececeeeeseceeceaueueceeeeaeeaeseeesseauaeeeeeeesaeaeeseeenees Page iv 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual 5 1 5 1 5 3 5 3 5 4 5 6 6 1 6 1 SECTION 7 STEERING AND FRONT SUSPENSION General Information Steering Wheel Steering Wheel Removal Steering Wheel Installation Steering Column Steering Column Removal Steering Column Installation ccccccsceeeeeeeeeeeeeeeeeeeeeaaeeeesaeeeseaeeseeaeeesaaaeseeeeeesaaesseaeeeseaeeeseaseseaes Rack and Pinion Rack and Pinion Removal Rack and Pinion DISASSOMDIy n
198. ng a crisscross pattern to 55 ft lb 74 6 N m 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 8 1 ER WHEELS AND TIRES Tires TIRES See General Warnings Section 1 Page 1 1 TIRE REMOVAL NOTE Tire must be removed or installed from the valve stem side of the rim 1 Remove the tire and wheel assembly from the vehicle as instructed above 2 Remove the valve cap and valve core and allow air to escape from the tire 3 If possible use a tire machine to remove the tire from the rim 3 1 Ifa tire machine is not available loosen both tire beads by applying pressure to the tire side walls and pushing the tire bead away from the rim flange and into the rim well Figure 8 1 Page 8 2 Detail A 3 2 With the valve stem side of the wheel up use a tire tool to carefully start the upper bead over the edge of the wheel rim Figure 8 1 Page 8 2 Detail B CAUTION e To avoid damage to the tire do not use excessive force when starting the bead over the edge of the rim 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 TOOL UPPER TIRE BEADS TIRE BEADS POSITIONED IN IN RIM W
199. ng 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 15 Page 11 30 CAUTION e 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 first Tighten battery terminals to 110 in lb 12 4 N m 6 With the Tow Run switch in the TOW position the multimeter should indicate zero volts 7 Place the Tow Run switch in the RUN position 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11 29 ELECTRICAL SYSTEM AND TESTING Test Procedures Test Procedure 9F Pin 9 Continued SPEED CONTROLLER 200 DCV SETTING READING WITH TOW RUN SWITCH IN RUN POSITION Figure 11 15 Pin 9 Test 8 With the Tow Run switch in the RUN position the multimeter should indicate full battery voltage approx imately 48 volts 9 If any other reading is obtained check the following items e Continuity of the wires in the wire harness e Tow Run switch for proper operation See Test Procedure 6 Tow Run Switch on page 11 19 Test Procedure 9G Pin 10 See General Warnings Section 1 Page 1 1 Pin 10 in the 16 pin connector provides a connection point for the key swit
200. nnector on page 11 22 Test REVERSE INPUT 4 1 Access the Test menu and select REVERSE INPUT by using the SCROLL DISPLAY buttons The IQDM should indicate OFF when the Forward Reverse switch is in the NEUTRAL or FORWARD position 4 2 Place the Forward Reverse switch in the REVERSE position The IQDM should indicate that REVERSE INPUT is ON If the IQDM indicates any other reading check vehicle wiring See Wiring Diagrams on page 11 2 Also check the 16 pin connector at the speed controller See Test Pro cedure 9 16 Pin Connector on page 11 22 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 Reverse Rocker Switch Test without the I QDM Handset Forward Reverse Rocker Switch Test without the IQDM Handset at Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 Remove the two screws securing the rocker switch case to the vehicle body Remove switch from car See Forward Reverse Rocker Switch Removal Section 12 Page 12 3 Disconnect the three wires from the rocker switch Using a multimeter set to 200 ohms place the black probe on the blue wire terminal 3 position on the rocker switch and place the red probe on the red wire terminal 2 position With the switch in NEUTRAL or REVERSE there should be no continuity With the switch in FOR
201. ns and frayed wiring they must be replaced when worn or damaged If charger plug or receptacle show signs of corrosion or the plug is difficult to insert or remove the receptacle contacts and plug terminals should be cleaned with a good electrical contact cleaner or lightly sprayed with electrical contact cleaner The plug should then be inserted and removed several times to ensure ease of insertion ease of removal and good electrical contact Testing the Charger Receptacle See Test Procedure 12 Section 11 Page 11 33 See also the appropriate battery charger maintenance and service manual Charger Receptacle Inspection Inspect the receptacle for cracks loose connections and frayed wiring NOTE Disassembly of the charger receptacle for the purpose of removal or installation is not recom mended 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 12 13 ELECTRICAL COMPONENTS Charger Receptacle BLACK TO CONNECTOR RED TO BATTERY 1 POST TYPICAL 3 PLACES Figure 12 11 Charger Receptacle Charger Receptacle Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 Remove electronic module cover Remove kick plate See Kick Plate and Charger Receptacle Bezel Section 4 Page 4 7 Remove the 10 gauge red wire from the positive post of battery no 1 Figure 12 11 Page 12 14 Disconnect th
202. ntroller is shut off disabling the vehi cle operating circuit and zero speed detect allowing the vehicle to be towed Motor Protection Circuit The operator should never attempt to hold the vehicle on an incline by press ing the accelerator pedal instead of the brake pedal 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 unexpected vehicle movement if the key switch is turned ON after the accelerator is pressed or the accelerator pedal is pressed when Forward Reverse switch is used to change the direction of travel The vehicle will not move until the accelerator is released and pressed again When this situation arises a HPD 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 Onboard Computer OBC The OBC 1 monitors battery condition 2 monitors the number of energy units used by the vehicle 3 determines the number of energy units required to recharge the batteries and shuts the charger off when this number is reached 4 determines when to activate regen erative motor braking 5 locks out vehicle movem
203. o 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 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 6 7 e WHEEL BRAKE ASSEMBLIES Brake Shoe Installation Brake Shoe Installation Continued 7 2 Using 90 internal snap ring pliers 0 090 tip CCI P N 1012560 attach the internal retaining ring into the axle tube hub so that it seats against the axle bearing assembly and into the machined slot in the inside wall of the axle tube hub Figure 6 3 Page 6 2 7 3 Place a 1 4 to 3 8 inch 6 10 mm diameter rod against the retaining ring and tap lightly at four or five locations to ensure it is properly seated See following WARNING A WARNING e Be sure retaining ring is properly seated in groove If ring is not properly installed the axle assembly will separate from the transaxle and damage the axle assembly and other components Loss of vehicle control could result in severe personal injury or death A CAUTION e Before installing axle shaft clean any residual oil from the exposed end of the axle tube and from the oil seal area 8 Install the brake drum and make sure that it is properly seated See following NOTE NOTE If drum installation is di
204. o 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 OBC Will Not Communicate With The CDM CDM battery is discharged Replace CDM battery 8 Failed Dash Light Failed CDM unit Replace CDM OBC program is locked up Remove battery lead and discharge the speed controller See the instructions in the WARNING on page 11 1 After a short time replace the lead and restart the OBC Failed OBC Replace OBC OBC is ina powerdown mode Restart OBC by driving vehicle or by connecting charger DC plug More than 75 EUs or 75 of energy removed from batteries Recharge Batteries Figure 11 20 Flow Chart CDM Troubleshooting Guide 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual SECTION 12 ELECTRICAL COMPONENTS A DANGER e See General Warnings Section 1 Page 1 1 A WARNING e See General Warnings Section 1 Page 1 1 KEY SWITCH See General Warnings Section 1 Page 1 1 Testing the Key Switch See Test Procedure 8 Section 11 Page 11 20 Key Switch Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in
205. ollowing items e Continuity of the wires in the wire harness e Onboard computer for proper operation See Test Procedure 11 Onboard Computer Gray Wire on page 11 33 e Tow Run switch for proper operation See Test Procedure 6 Tow Run Switch on page 11 19 Test Procedure 9C Pin 6 See General Warnings Section 1 Page 1 1 Pin 6 in the 16 pin connector provides a connection point for the MCOR limit switch 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 just forward of each spring mount See WARNING Lift only one end in General Warnings Section 1 Page 1 2 3 Disconnect the 16 pin connector at the speed controller 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11 25 ELECTRICAL SYSTEM AND TESTING Test Procedures Test Procedure 9C Pin 6 Continued SPEED CONTROLLER 200 DCV SETTING READING WITH OBC POWERED UP AND ACCELERATOR PEDAL PRESSED Figure 11 12 Pin 6 Test 4 Using a multimeter set for 200 volts DC insert the red probe of the multimeter into pin 6 green wire of the 16 pin connector See following CAUTION Using an alligator clip connect the black probe to the B terminal of
206. om out against the transaxle housing Figure 15b 15 Page 15b 10 There will be approximately 1 16 inch 1 6 mm gap between the motor adapter ring and transaxle housing as shown Figure 15b 23 Page 15b 14 1 16 INCH 1 6 MM CHAMFER SHAFT END Figure 15b 22 Clean Chamfer and Input Shaft End Figure 15b 23 Gap at Motor and Transaxle 4 2 Loosely install the four bolts that secure the motor to the transaxle Do not tighten 4 3 Begin finger tightening the bolts 1 and 2 in the sequence indicated Figure 15b 24 Page 15b 15 Continue tightening by hand until the motor is seated in the transaxle housing See following CAUTION and NOTE CAUTION e Make sure the motor is properly seated in the transaxle housing NOTE 4 4 4 5 4 6 4 7 4 8 4 9 4 10 Page 15b 14 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 Tighten the right bolt 1 to 65 in lb 7 3 N m Tighten the left bolt 2 to 65 in lb 7 3 N m Tighten the center bolt 3 to 65 in lb 7 3 N m Figure 15b 24 Page 15b 15 Tighten the bolt 4 inserted through the L bracket to 155 in lb 17 5 N m Figure 15b 24 Page 15b 15 Install the motor wires making sure they are connected to the correct motor terminals and that the terminal orientation is correct See Wiring Diagrams Section 11 Page 11 2 Tighten the terminal retaining nuts to 65 in
207. own Tighten the hardware to 124 in lb 14 N m Secure the front of the canopy 9 to the front supports 1 with four spacers 10 bolts 11 and cap nuts 12 Tighten the hardware to 10 ft lb 13 6 N m Secure the rear of the canopy 9 to the rear canopy support 6 with four bolts 13 and cap nuts 14 Tighten the hardware to 10 ft lb 13 6 N m Tighten the four bolts 2 installed in step 1 2 to 18 ft lb 25 N m Secure each front support cover 4 with one screw 5 Tighten the hardware to 53 in Ib 6 N m Page 4 20 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual SECTION 5 ACCELERATOR AND BRAKE PEDAL GROUP A DANGER e See General Warnings Section 1 Page 1 1 A WARNING e See General Warnings Section 1 Page 1 1 PEDAL GROUP See General Warnings Section 1 Page 1 1 PEDAL GROUP 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 turnbuckle 6 6 Nut 4 has a left hand thread A x M Fe R gt a T Kee Ee Figure 5 1 Pedal Group Access 2005 Precedent IQ System Electric Golf Ca
208. p the battery from bouncing Battery life may be severely shortened if the battery hold downs are too loose Battery hold downs should be tightened to 97 in lb 11 N m Excessive vibration 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 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 1 BATTERY CHARGING See General Warnings Section 1 Page 1 1 The charger supplied with the Club Car electric vehicle resolves the most common problems associated with battery charging Undercharging and overcharging are prevented provided the charger is allowed to shut off by itself Also all cells are automatically given an equalization charge at low current which prolongs battery life Batteries should never be left in a discharged state as this too affects the internal components and can reduce the capacity of the battery The batteries should be charged every day they are used However the batteries should not be charged if they have not been used Page 13 4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual BATTERIES Battery Charging CHARGER SHUTS OFF AFTER 16 HOURS Thi
209. pports 1 and rear support 6 Remove screws 5 securing front canopy support covers to front body Slide canopy support covers 4 up front canopy supports 1 to gain access to bolts 2 Remove two bolts 2 from each front canopy support 1 and remove the canopy supports from the vehi cle Remove two bolts 8 from the rear support 3 and remove rear support from vehicle FOUR PASSENGER CANOPY INSTALLATION 1 Install the front canopy supports 1 1 Ensure the front supports are properly oriented to the correct side of the vehicle as shown Figure 4 13 Page 4 19 The lower profile of each support follows the profile of the vehicle If the supports are placed on the wrong side of the vehicle they will not follow the vehicle s profile 1 2 Align the holes in the lower portion of each front support 1 with the corresponding holes in the vehicle Insert two bolts 2 through each front support into the threaded holes in the vehicle The bolts are color coded with gold thread lock Only finger tighten the bolts at this time 1 3 Slide the front support covers 4 over the front supports 1 The covers are marked DRIVER and PASS to identify them as going on the driver side or passenger side respectively Do not install the screws 5 yet Remove the two bolts that secure the hip restraint 15 to the seat supports 7 Align the rear canopy support 6 with the top of the seat supports 7 and secure with two bolts 8 as sh
210. probe on the negative post of battery no 4 and place the red probe on the charger recep tacle socket connected to the red 10 gauge wire The reading should be 48 50 volts full battery voltage 2 Ifthe reading is zero volts check the continuity of the 10 gauge red wire from the positive post of battery no 1 to the receptacle socket 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11 33 ELECTRICAL SYSTEM AND TESTING Test Procedures TEST PROCEDURE 13 MOTOR SPEED SENSOR See General Warnings Section 1 Page 1 1 Motor Speed Sensor Test with the IQDM Handset A CAUTION e Perform the following procedure only on a level surface To avoid injury or property damage ensure that the path of the vehicle is clear before pushing vehicle Turn the key switch to the OFF position and place the Forward Reverse switch in the NEUTRAL position 2 Connect the IQDM to the vehicle as described in the IQDM Owner s Manual 3 Access the Test menu and select SPEED PULSES by using the SCROLL DISPLAY buttons The IQDM should indicate OFF when the vehicle is at rest While monitoring the IQDM display screen slowly push the vehicle a short distance about 3 feet 1 meter The IQDM should indicate ON for speed sensor pulses while the wheels are in motion If the IQDM does not indicate ON while the wheels are in motion proceed to the following procedure Motor Speed Sensor Test without the IQDM Handset Motor
211. prove to be quite time consuming Number ing the vehicles and the chargers and returning each vehicle to its designated charger each night can signif icantly reduce the amount of time spent troubleshooting a problem 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 13 5 BATTERIES Battery Troubleshooting Chart BATTERY TROUBLESHOOTING CHART Vehicle not operating to expectation Fully Charge Batteries Battery Charger Test Reading below 6 amps and on charge EE more voltage above 56 volts Check electrical system and charger for problems SeeTroubleshooting Guide On Charge Voltage Test If problem is not found go to on charge voltage test S vr Any reading below 9 3 volts and not b ihj All readings below 9 3V but within 0 7V within 0 7 volts of those batteries All readings above 9 3V and within 0 7V above 9 3 volts replace battery Possible old batteries Hydrometer Test Go to hydrometer testing No apparent problems Replace any battery with a variation Entire battery set with specific gravity of more than 50 points of specific gravity readings below 1 250 is being between cells or has a cell with no consistently undercharged i reading at all Evaluate charging practices Discharge Test If discharge time is less than 60 minutes If discharge time is 60 minutes or replace all batteries below 6 7 volts more problem is not with the batteries Figure 13 3 Bat
212. r Maintenance and Service Manual Page 5 1 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group TYPICAL 2 PLACES GE K Y o 2 Ce N DN Ss f PEN j SN ELECTRICAL KG XG CONNECTIONS Figure 5 2 Pedal Group Page 5 2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Fe Pedal Group Removal Continued 7 Loosen turnbuckle 6 until the threaded rod from the pedal group is free of the turnbuckle 8 Remove two screws 2 on the driver side of the pedal group and two screws 1 on the passenger side of the pedal group 9 Slightly lift pedal group from the vehicle to gain access to the connections to the MCOR on the passenger side of the pedal group 10 Disconnect the electrical connectors at the MCOR 11 Remove two screws 1 to separate the MCOR from the pedal group Figure 5 3 Page 5 3 Figure 5 3 MCOR Removal MCOR The pedal group for the 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 place with screws 1 and washers 2 Figure 5 4 Page 5 5 When shields are replaced tighten screws
213. r mallet and tapping lightly around the edge of the cap Repeat the procedure for the opposite wheel Install wheels and finger tighten lug nuts NOD Lower the vehicle and finish tightening lug nuts using a crisscross pattern to 55 ft lb 74 6 N m Figure 7 20 Front Wheel Hub 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 7 17 SECTION 8 WHEELS AND TIRES A DANGER e See General Warnings Section 1 Page 1 1 A WARNING e See General Warnings Section 1 Page 1 1 GENERAL INFORMATION Maximum tire life and good vehicle handling qualities are directly related to proper wheel and tire care e Keep tires properly inflated See Section 2 Vehicle Specifications e Keep lug nuts properly tightened e Keep the front end aligned and adjusted A WARNING e Tires 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 nuts and remove the wheel WHEEL INSTALLATION 1 Install wheel s and tighten the lug nuts using a crisscross pattern until they are snug 2 Lower the vehicle and finish tightening lug nuts usi
214. re front lower edge of rear beauty panel mates with the kick plate Tighten screws to 3 3 ft lb 4 5 N m Install two front screws 8 to secure the rear beauty panel Tighten screws to 3 7 ft lb 5 N m Install floor mat See Floor Mat and Retainers Section 4 Page 4 6 Snap charger bezel 4 in place on the kick plate 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 4 7 BODY AND TRIM Rear Body Two Passenger Vehicles TYPICAL 3 PLACES REAR BODY TWO PASSENGER VEHICLES See General Warnings Section 1 Page 1 1 UNIVERSAL ACCESSORY MOUNTING The Structural Accessory Module SAM includes two threaded inserts on both the driver side and the pas senger side Figure 4 6 Page 4 8 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 6 Universal Accessory Mounting Page 4 8 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual BODY AND TRIM Rear Body Two Passenger Vehicles 2 PLACES 1 aaa TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES Figure 4 7 Backrest and SAM 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 4 9 BODY AND TRIM Rear Body Two Passenger Vehicles BACKREST AND STRUCTURAL ACCESSORY MODULE SAM
215. re that requires movement of the wheels lock the brakes Page 15b 2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual MOTOR MODEL EJ4 4001 Motor JACK STAND UNDER ALUMINUM FRAME RAIL Figure 15b 1 Lift Vehicle with Floor Jack Figure 15b 2 Vehicle Supported on Jack Stands 5 Remove both rear wheels 6 Remove the nut cup washer and bushing from the bottom side of the shock absorber Compress the shock absorber pushing upwards to move it out of the way Figure 15b 3 Page 15b 3 7 Remove the nuts and bolts mounting the rear leaf springs to the shackles 8 To gain easier access to the motor lower the transaxle as 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 15b 3 Page 15b 3 Figure 15b 3 Lower Axle 9 Remove the four bolts that mount the motor to the transaxle Figure 15b 24 Page 15b 15 See fol lowing CAUTION A CAUTION e Do not position fingers under motor when sliding motor off of the input shaft in step 9 Fingers may get pinched when motor disengages 10 Carefully slide the motor away from the transaxle until the motor spline disengages the input shaft and remove the motor from the vehicle 2005 Precedent IQ System E
216. rocedure that requires movement of the wheels lock the brakes Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance severe personal injury or death Any modification or change to the vehicle that affects the stability or handling of the vehicle or increases maximum vehicle speed beyond 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 clothing or jewelry such as rings watches chains etc when servicing the vehicle or battery charger Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Prior to leaving the vehicle unattended or servicing the vehicle turn the key switch OFF remove the key and place the Forward Reverse switch in the NEUTRAL position Chock the wheels when servicing the vehicle Place Tow Run switch in the TOW position before disconnecting or connecting the batteries Failure to heed this warning could result in a battery explosion or severe personal injury To avoid unintentionally starting the vehicle disconnect the batteries as shown Figure
217. roubleshooting sine eeu a Shee hee eh Ae RA ni Ni Ah Baia Ne iets 11 7 Troubleshooting the Vehicle with the IQDM c cccesccceeeeeeceeneeeeecaeeesaaeeseeeeeesaaeeseneeeesaeeeteneeeeaas 11 7 Troubleshooting Guide Leeder laden achive ian eee ale 11 8 Bell ele tt e BEIEN 11 11 Test Procedures eu orario aen e ia ia a i ENEE gegen 11 13 Index of Test Froe ei ri a aAA cass E TAA AA 11 14 Communication Display Module CDM cccsceeeeeeeeeeeeeeeeeeeeeeesecaeeesaaaeseceeeesaaeseeaeeeseaeeeteaeeee 11 38 Using the CDM to Retrieve Data from the Onboard Computer cccceeeceeeeeeeeeeeeeeeeeeeeeneeeees 11 39 CDM Troubleshooting Guides EE 11 40 Page vi 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual SECTION 12 ELECTRICAL COMPONENTS AEE EEEE EE T E E E T e rg 12 1 Baten Warring Ee Lu 12 3 Forward Reverse Rocker SwWitCh irritues arie reinan EE EREATARA ARRATERA EA EE AEAEE TARARE ARES 12 3 Electronics Module Cover senieiieniseveniaen a a gate e a aa a ana 12 5 TOW RUN N EE 12 6 Motor Controller Output Regulator MCOR ceeceeeeeeeeeeeeeeeeeeeaeeeeeeeeeeaaaeeeeeeeesaaeeeeeaeesesaeeeseneeesaas 12 7 Reverse BuZZeM Leet ee deet Eegen eege as eghd Seep Ghia EE ee ee de 12 8 Electonics Module ube canes e aa kee th ege EE EELER 12 10 Solid State Speed Controller 2 0 eeccecccecceeeceeeeeeeeeeeeeeeneesecaeeeeeaaeseeeeeesaaaeeseeeeeseaaesseaaeeseeeeeseaeeeeeeesaas 12 11 EL In NEE 12 1
218. rward 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 worn brake shoes and when the drums cannot be removed by normal methods perform Step 7 of Brake Shoe Removal on page 6 2 then continue with this procedure Although step 7 below allows easier access to the brake shoes it is not imperative to do so in order to remove the brake shoes 7 Remove the axle 7 1 Using 90 snap ring pliers CCI P N 1012560 remove the axle retaining ring 1 Figure 6 3 Page 6 2 7 2 Pull the axle shaft 2 from the axle tube Figure 6 3 Page 6 2 8 Remove bow tie locking pin 13 and clevis pin 12 from brake cable Figure 6 4 Page 6 3 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 6 9 e WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation Brake Cluster Removal Continued 9 Remove four bolts 11 and lock nuts 10 that mount the brake assembly to the transaxle Figure 6 4 Page 6 3 10 Remove brake assembly from transaxle BRAKE CLUSTER INSTALLATION 1 Install in reverse order of disassembly Use new bow tie locking pins when installing brake cables A CAUTION e Before installing
219. ry CONTROL ARM INSTALLATION 1 Install the control arm in reverse order of removal Tighten the control arm bolts 11 and 19 to 20 ft lb 27 N m Figure 7 18 Page 7 15 Tighten three rack and pinion mounting bolts 17 to 22 ft lb 30 N m 2 Install the wheels and adjust the wheel alignment as instructed on page 7 10 SHOCK ABSORBER REMOVAL 1 Inspect the shock absorbers for fluid leakage at the point where the shaft enters the shock absorber body Leaking shock absorbers should be replaced 2 Remove the upper bolt 18 Figure 7 18 Page 7 15 3 Remove the lower bolt 10 4 Remove the shock absorber SHOCK ABSORBER INSTALLATION NOTE When installing shock absorbers make sure front shocks have identical part numbers 1 Install the shock absorber by reversing the removal procedure 2 Tighten the bolts to 20 ft lb 27 N m Page 7 14 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual STEERING AND FRONT SUSPENSION Front Suspension Components Figure 7 18 Upper Front Suspension Assembly 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 7 15 STEERING AND FRONT SUSPENSION Front Suspension Components Figure 7 19 Lower Front Suspension Assembly Page 7 16 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs FRONT WHEEL BEARINGS AND HUB
220. s See Section 8 Wheels and Tires Vehicle operates but motor braking function does not Wiring improperly wired Check vehicle wiring See Wiring Diagrams on page 11 2 Speed sensor disconnected or failed Test Procedure 13 Motor Speed Sensor on page 11 34 Vehicle will run in forward but not in reverse or will run in reverse but not forward Forward Reverse rocker switch improperly wired Test Procedure 15 Forward Reverse Rocker Switch on page 11 36 Motor improperly wired Check motor wiring See Wiring Diagrams on page 11 2 Speed controller improperly wired or failed speed controller FET Check vehicle wiring See Wiring Diagrams on page 11 2 Vehicle operates but battery charger does not charge batteries Onboard computer gray wire Test Procedure 11 Onboard Computer Gray Wire on page 11 33 Battery charger connections loose wires at receptacle or batteries Check wire connections and tighten if necessary Battery charger Refer to the appropriate battery charger maintenance and service manual Page 11 12 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL SYSTEM AND TESTING Test Procedures TEST PROCEDURES Using the following procedures the entire IQ electrical system can be tested without major disassembly of the vehicle A WARNING e If wires are removed or replaced make sure
221. s as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 See following NOTE NOTE Wait at least 90 seconds for the capacitors in the speed controller to discharge The capacitors in the speed controller must be fully discharged in order to reboot the OBC 2 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m and coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 3 Place Tow Run switch in the RUN position 4 Test drive the vehicle If the vehicle functions normally the problem is corrected If the problem still exists refer to Wiring Diagrams on page 11 2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11 37 ELECTRICAL SYSTEM AND TESTING Communication Display Module CDM TEST PROCEDURE 18 BATTERY WARNING LIGHT See General Warnings Section 1 Page 1 1 1 Reboot the OBC and drive the vehicle a short distance When vehicle is first driven the battery warning light should illuminate for 10 seconds See Test Procedure 17 Rebooting the Onboard Computer on page 11 37 If the battery warning light does not illuminate when rebooting the OBC proceed to step 2 2 Turn key switch OFF place Tow Run switch in TOW and place Forward Reverse rocker switch in NEU TRAL 3 Disconnect the six pin connector at
222. s may be due to 1 new batteries 2 hard use or 3 cold temperatures A catch up charge may be neces sary when these conditions are present On those days when all or some of the vehicles do not get used check the batteries for state of charge Any battery with a specific gravity lower than 1 250 will need a catch up charge If the problem continues after a catch up charge has been performed check the battery charger See Section 14 Battery Charger DEEP DISCHARGE Never discharge batteries to the point the vehicle will no longer operate This will considerably shorten the cycle life of the batteries and may permanently damage the batteries It is possible the batteries will not accept a charge if they are completely discharged The deeper the discharge the harder it is on the batteries For this reason it is recommended that Club Car electric vehicle batteries be charged after each use pro vided the charge cycle will not be interrupted and the charger will be allowed to shut off automatically Placing the batteries on charge after each use reduces the depth of discharge and prolongs battery life EARLY EXCESSIVE DISCHARGING When vehicle batteries are new they do not reach their full capacity until they have been used and recharged 20 to 50 times If they are excessively discharged early in their life their effective service life will be shortened It is advisable to limit the use of any vehicle with new batteries for at least the first
223. s of the vise to protect the rack from damage Tighten the ball joints to 60 ft lb 81 N m Tap a flange into the notch on the rack Figure 7 11 Page 7 9 Place a few drops of Loctite 222 to the threads of the screw 14 Figure 7 5 Page 7 6 Install the rack guide 16 pressure spring 15 and screw 13 The screw should be threaded in until it bottoms out and then backed out 1 4 turn Figure 7 5 Page 7 6 Insert a 3 8 inch 1 4 drive deep well socket into the steering column end of the universal joint 2 and tighten the bolts 1 to 15 ft lb 20 3 N m Figure 7 13 Page 7 9 Use a torque wrench connected to the 3 8 inch deep well socket to measure the resistance of the rack and pinion Rotational resistance should measure 7 to 15 in lb 0 8 to 1 7 N m If measured resistance is not 7 to 15 in lb 8 to 1 7 N m adjust the screw 13 until correct setting is achieved Tighten the nut 14 to 28 ft lb 88 N m Figure 7 12 Page 7 9 NOTE When tightening the nut 14 make sure the screw 13 does not change adjustment Figure 7 12 14 15 16 Page 7 9 Install the two dust seal bellows 9 Figure 7 5 Page 7 6 Install new bellows clamps wire ties 10 and 21 Install the tie rod ends 12 to each end of rack 18 Tighten the tie rod end jam nuts 11 to 20 ft lb 27 N m Figure 7 5 Page 7 6 Page 7 8 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual STEERING AND FRONT SUSPENS
224. s on motor 3 Using a multimeter set to 200 ohms place black probe on motor housing Scratch through paint to ensure a good connection Place red probe on A1 A2 F1 and F2 terminals respectively Figure 15a 1 Page 15a 2 Multimeter should indicate no continuity If readings are incorrect motor will need to be removed from the vehicle and repaired by a qualified technician See Motor Removal on page 15a 3 3 1 An incorrect reading from the A1 or A2 terminal indicates three possible problems a grounded A1 or A2 terminal a grounded wire in the brush area or a grounded armature commutator An incor rect reading for the F1 or F2 terminal indicates a possible grounded F1 or F2 terminal or field coil 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15a 1 15A MOTOR MODEL 5BC59JBS6365 External Motor Testing External Motor Testing Continued Figure 15a 1 Motor Short Circuit Test TEST PROCEDURE 2 ARMATURE 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 Using two wrenches to prevent the posts from turning disconnect wires from the A1 and A2 terminals on the motor Using a multimeter set to 200 ohms place the red probe on the A1 terminal and black probe on the A2 terminal The multimeter should indicate continuity If the
225. sembly cover See Electronics Module Cover Installation on page 12 5 4 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m and coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 5 Place the Tow Run switch in the RUN position 6 Inspect the vehicle for proper operation A WARNING e Make sure that the vehicle operates in the forward direction when the Forward Reverse switch is in the FORWARD position e 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 e Make sure that the vehicle does not operate when the Forward Reverse switch is in the NEUTRAL position 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 12 11 ELECTRICAL COMPONENTS Solenoid SOLENOID Figure 12 10 Component Mounting Plate SOLENOID See General Warnings Section 1 Page 1 1 The solenoid is located on the passenger side of the electrical component mounting plate Testing the Solenoid See Section 11 Test Procedure 3 Page 11 16 and Test Procedure 14 Page 11 35 Solenoid Removal 1 S 3 4 5 Disconnect the battery cables as instru
226. 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 15a 15 Page 15a 13 2 4 The grease should be evenly distributed in the grooves to a width of approximately 3 8 inch 9 5 mm 2 5 Using a flat screwdriver clean the grease out of one of the grooves to allow air to escape when the motor is pushed onto the input shaft Page 15a 12 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual MOTOR MODEL 5BC59JBS6365 Motor Installation GREASE L 1 8 INCH 3 8 INCH 9 5 MM 3 1 MM Figure 15a 14 Grease on Putty Knife Figure 15a 15 Application of grease to Input Shaft Grooves 2 6 Check the chamfer and end of the input shaft to ensure these areas are completely clean of grease as shown Figure 15a 16 Page 15a 13 3 Install the molded bumper 3 1 With the flat side toward the bottom of the coupling install the molded bumper 30 into the motor coupling Figure 15a 10 Page 15a 8 See following NOTE NOTE The motor coupling and the new molded bumper must be free of grease and debris 3 2 Ensure that the installed bumper is seated at the bottom of the coupling 4 Install motor on transaxle 4 1 Slide the motor coupling onto the transaxle input shaft See following NOTE NOTE The coupling
227. stment eccentric 7 to 10 ft lb 13 5 N m Figure 7 15 Page 7 11 See also Figure 7 19 Page 7 16 Page 7 10 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual STEERING AND FRONT SUSPENSION PROPER ADJUSTMENT wa EQUAL SPACE BETWEEN TIRES AND FRAMING SQUARES IMPROPER CAMBER ADJUSTMENT UNEQUAL SPACE ku BETWEEN TIRES AND FRAMING SQUARES Figure 7 14 Check Camber Toe in Adjustment y Kess Kueb SS CM FN 7 MM DEEP WELL SOCKET Front Suspension Figure 7 15 Adjust Camber 1 On a level surface roll the vehicle forward then stop Make sure the front wheels are pointed straight ahead Do not turn the steering wheel again during this procedure 2 On each front tire mark as closely as possible the center of the tread face that is oriented toward the rear of the vehicle The marks 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 Figure 7 16 Check Toe In Figure 7 17 Adjust Toe In 4 Measure the distance between the marks on the forward facing surfaces of the tires Figure 7 16 Page 7 11 NOTE The front measurement must be less than the rear measurement 2005 Pre
228. talled the axle assembly will separate from the transaxle and damage the axle assembly and other components Loss of vehicle control could result in severe personal injury or death 5 Tighten lug nuts on rear wheels using a crisscross pattern to 55 ft lb 74 6 N m See Wheel Installa tion Section 8 Page 8 1 6 Adjust the brakes See Brake Cable Equalizer Adjustment on page 6 9 Page 6 10 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual WHEEL BRAKE ASSEMBLIES BRAKE CABLE REMOVAL AND INSTALLATION See General Warnings Section 1 Page 1 1 See also Warning on Page 6 1 Brake Cable Removal 1 10 11 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 Place chocks at the front wheels Gain access to the pedal group by removing the floor mat and access panel See Pedal Group Removal Section 5 Page 5 1 Loosen the two jam nuts 1 and 3 on either side of turnbuckle 2 Figure 6 19 Page 6 11 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 Loosen turnbuckle 2 until the bolt 5 is free of the turnbuckle Figure 6 19 Loosen Brake Cables Rotate the bolt 5 and equalizer bracket 4 to the upright position then slip the cable heads out of the bracket Remove nut 1 from the bolt 2 that secures front of t
229. tator should be cleaned and wiped dry Abnormalities identified during the inspection can help determine original cause of failure Slight roughness of the commutator can be polished smooth with 400 grit or finer sandpaper See following CAUTION and NOTE CAUTION e Do not use emery cloth to polish the commutator Particles of emery are conductive and may short circuit the commutator bars Do not use oil or lubricants on the commutator or brushes NOTE Oil on the commutator may indicate a faulty transaxle input shaft oil seal Armature Ground Test A CAUTION e 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 ohms place one probe on the commutator and the other on the armature core The multimeter should indicate no continuity Figure 15a 7 Page 15a 6 If the reading is incor rect replace the armature Figure 15a 7 Armature Test FIELD WINDINGS INSPECTION Burned or scorched insulation on the field windings indicates the motor has overheated due to overloads or grounded or shorted coil windings If the insulation on the field windings is scorched replace the motor or the stator shell assembly Page 15a 6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual MOTOR MODEL 5BC59JBS6365 Motor Component Testing and Inspection MOTOR C
230. teering gear 5 To minimize corrosion apply a light coat of anti seize lubricating compound to the threads where the tie rod ends are installed TIE ROD INSTALLATION 1 Thread tie rod ends 12 onto steering gear to a depth of 1 2 inch 12 5 mm Figure 7 18 Page 7 15 A WARNING e The tie rod ends must be threaded into the rod at least 5 16 of an inch 8 mm Failure to thread deep enough may cause tie rod ends to separate from the rod during adjustment or while being operated possibly resulting in loss of vehicle control and severe personal injury 2 Install tie rod ends 12 into the spindle tabs Install the retaining nuts 14 and retaining pins 15 Figure 7 18 Page 7 15 3 Adjust wheel toe in See Toe in Adjustment on page 7 11 Page 7 12 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual STEERING AND FRONT SUSPENSION Front Suspension Components LEAF SPRING REMOVAL 1 Loosen lug nuts on both front wheels and raise front of vehicle with a chain hoist or floor jack Place jack stands under the aluminum rails of the vehicle frame just aft of the front suspension Lower the vehicle onto the jack stands See General Warnings Section 1 Page 1 1 Remove both front wheels Remove the bolts 8 from the bottom of each kingpin 7 Figure 7 19 Page 7 16 Remove the four bolts 17 and bottom spring plate 16 Remove leaf spring 13 om o E o Check the condition of the urethane bushin
231. tery Troubleshooting Chart Page 13 6 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual BATTERIES Battery Testing BATTERY TESTING See General Warnings Section 1 Page 1 1 Four tests have been developed to help diagnose problems with batteries that have not performed as expected Because each test becomes progressively more detailed and time consuming begin with the first test and follow through with the other tests until the problem has been identified as outlined in the Battery Troubleshooting Chart Figure 13 3 Page 13 6 BATTERY CHARGER TEST The easiest way to monitor the condition of a vehicle s batteries is simply to observe the reading on the battery charger ammeter at the end of the charge cycle After a full charge disconnect the charger DC plug wait 20 to 30 seconds and reconnect the charger DC plug The ammeter needle will jump to 15 amps or more and then taper to below 6 amps within 10 to 20 minutes indicating sound fully charged batteries Continued poor performance may indicate a problem in the vehicle electrical system brakes or battery charger H the problem is not found in the vehicle or charging system proceed to the on charge voltage test Batteries that remain at 8 amps or higher should be tested further using the on charge voltage test ON CHARGE VOLTAGE TEST When the batteries are fully charged disconnect the charger DC plug Wait 20 to 30 seconds and reconnect the DC plug to r
232. tery terminals to 110 in lb 12 4 N m and coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 5 Place the Tow Run switch in the RUN position 6 Inspect the vehicle for proper operation A WARNING e Make sure that the vehicle operates in the forward direction when the Forward Reverse switch is in the FORWARD position e 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 e Make sure that the vehicle does not operate when the Forward Reverse switch is in the NEUTRAL position Page 12 4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL COMPONENTS Electronics Module Cover ELECTRONICS MODULE COVER See General Warnings Section 1 Page 1 1 The electronics module cover needs to be removed to gain access to the electronics module the Tow Run switch and 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 5 3 Hold battery wire out of way and lift cover 2 off the vehicle Electronics Module Cover Installation 1 Hold battery wire out of way and place cover
233. the frame crossmember forward of the spring mounting tabs Lower the vehi cle to let the jack stands support the vehicle Figure 9 2 Page 9 3 See following WARNING 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 9 1 Leaf Springs Two Passenger Vehicles Se ES a ie ONS Sen lt 2 _ e el IRA A N PPI a e yoo G E TYPICAL ON EACH SIDE OF VEHICLE BRAKE CABLE HANGER MOUNTING ES REAR SUSPENSION Figure 9 1 Rear Suspension Assembly and Mounting Two Passenger Vehicles 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 9 2 REAR SUSPENSION Leaf Springs Two Passenger Vehicles RER Leaf Spring Removal Two Passenger Vehicles Continued A WARNING e Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 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 the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 2 Place a floor jack under the transaxle differential casing to support but not lift the drivetrain Raise it just enough to relieve tension on the shock absorbers without compressing them 3 Remove the tire and wheel assembly on t
234. the multimeter into pin 8 white 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 14 Page 11 29 CAUTION 13 e Do not fully insert probes into the 16 pin plug Doing so can result in a poor connection Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten battery terminals to 110 in Ib 12 4 N m Place the Tow Run switch in the RUN position and the Forward Reverse switch in the NEUTRAL posi tion The multimeter should indicate zero volts DC at this time While monitoring the multimeter place the Forward Reverse switch in the REVERSE position The mul timeter should still indicate zero volts Place the Forward Reverse switch in the FORWARD position The multimeter should indicate full battery voltage approximately 48 volts Insert the red probe of the multimeter into pin 16 blue wire of the 16 pin connector Leave the black probe alligator clip connected to the B terminal of the speed controller See previous CAUTION Place the Forward Reverse switch in the NEUTRAL position The multimeter should indicate zero volts DC at this time While monitoring the multimeter place the Forward Reverse switch in the FORWARD position The mul timeter should still indicate zero volts Place the Forward Reverse switch in the REVERSE position The mul
235. tice and without the obligation of making changes to units previously sold There are no warranties expressed or implied in this manual See the limited warranty found in the vehicle owner s manual or write to Club Car Inc PO BOX 204658 Augusta Georgia 30917 4658 USA Attention Warranty Department Page ii 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual CONTENTS SECTION 1 SAFETY General Warnings eisian ieni eh i Neel eel ae de ee a ee 1 1 SECTION 2 VEHICLE SPECIFICATIONS SECTION 3 GENERAL INFORMATION Serial Number Identification 22 0 2 cccececceeceeeceneee cece ee eeaaeeeeeeeeeceaeeeceeeseaaeeeseaeeseeaeeesaaeeseaneeesaeseeeeeeaas 3 1 Safety COMMITTEE coe natin eee A i ee el ee a Ae ea 3 2 Storag vases ieee Reed ei ea iva see ee at nate 3 2 Preparing the Electric Vehicle for Extended Off Season Storage ccccccceseeeeseeeeeeeeeeesteeneneees 3 3 Returning the Stored Electric Vehicle to Service e ceeeeceeeeeceeeeeeeceeeeeeeeeeeseaeeeseaaeseseeeeeaeeseneees 3 3 SECTION A BODY AND TRIM Cleaning the Vehicle AA 4 1 DO EE 4 1 Front amd Rear ele le ET 4 2 stress Lin s or Streaks ie iach Soeg e aii Le a iit eee eter eed 4 2 Minor Impact Damage Deformations 00 0 ccc ccecceceeceeeeeeeeeeeeeeeeeeaaeeeeeeeaaeeeeeeeaaaeeeeeeeaaeeeeeeeaaeeeeneeaaes 4 2 Minor Scratches and Surface Blemishes cccceceeseeeeeceeeeeeaeeeeeeeeeeeaaeeeeeeeesaeeeseneesseueeeeenaeess
236. timeter should indicate full battery voltage approximately 48 volts If any other reading is obtained check the following items e Continuity of the wires in the wire harness e Forward Reverse switch for proper operation See Test Procedure 15 Forward Reverse Rocker Switch on page 11 36 Page 11 28 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL SYSTEM AND TESTING Test Procedures SPEED CONTROLLER 200 DCV SETTING READING WITH TOW RUN SWITCH IN RUN AND FORWARD REVERSE SWITCH IN FORWARD Figure 11 14 Pins 8 and 16 Test e Tow Run switch for proper operation See Test Procedure 6 Tow Run Switch on page 11 19 Test Procedure 9F Pin 9 See General Warnings Section 1 Page 1 1 Pin 9 in the 16 pin connector provides a connection point for the Tow Run switch to the speed controller The switch provides a 48 volt signal to the speed controller through pin 9 when the Tow Run switch is in the RUN position 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 See WARNING Lift only one end in General Warnings Section 1 Page 1 2 3 Disconnect the 16 pin connector at the speed controller 4 Usi
237. upper edge properly engage with the corresponding slots on the dash assembly Ensure that there are no wires exposed or pinched during positioning 3 3 Secure instrument panel to the dash assembly with three screws 1 Tighten screws to 1 8 ft lb 2 5 Nem 4 Place the Tow Run switch in the TOW position and connect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m and coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion Page 12 2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL COMPONENTS Battery Warning Light BATTERY WARNING LIGHT See General Warnings Section 1 Page 1 1 Testing the Battery Warning Light See Test Procedure 18 Section 11 Page 11 38 Battery Warning Light 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 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 positive cable first Tighten battery terminals to 110 in lb 12 4 N m and coat terminals with Battery Term
238. val Section 12 Page 12 7 5 4 Ifthe voltage reading is zero volts when the accelerator pedal is pressed check the limit switch cir cuit using the following test procedures 5 4 1 Using a multimeter set to 200 volts DC place black probe on battery no 4 negative post and the place red probe with insulation piercing probe on the blue wire where it connects to the MCOR With the key switch ON the reading should be approximately 48 volts full battery voltage 5 4 2 If the reading is zero volts check the continuity of the blue wire that goes from the key switch to the MCOR 5 4 3 If the reading is approximately 48 volts proceed to the following step 5 4 4 Using a multimeter set to 200 volts DC place the black probe on the battery no 4 neg ative post and place the red probe with insulation piercing probe on the green 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 replace the MCOR See MCOR Removal Section 12 Page 12 7 TEST PROCEDURE 9 16 PIN CONNECTOR See General Warnings Section 1 Page 1 1 1 Disconnect the battery cables as instructed
239. ve Pinion from Housing Figure 7 9 Remove Bearing from Pinion 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 7 7 STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION ASSEMBLY 1 Apply a liberal amount of EP grease to the teeth of the rack 18 then slide the rack through the bushing 7 and housing 17 Figure 7 5 Page 7 6 CAUTION e In step 2 do not press against the outer race of the bearing If the pinion bearing 4 was removed grease a new bearing before installation Press new bearing onto pinion shaft exerting all pressure on the inner race Then install the C type stop ring 3 See previous CAUTION Install pinion 5 and bearing 4 assembly into the housing 17 Make sure the rack gear teeth will mesh with the gear teeth on the pinion The rack may need to be rotated slightly while lightly tapping on the pin ion bearing assembly with a rubber mallet See following CAUTION CAUTION e Do not force the pinion bearing assembly into the housing The gear teeth or the small bearing could be damaged Install the large snap ring 2 Use a socket to apply pressure evenly and press in a new dust seal Figure 7 10 Page 7 9 Apply a small amount of grease to the rack guide 16 where it comes into contact with the rack 18 Figure 7 5 Page 7 6 Install the ball joints 8 onto the rack 18 by securing the rack in a vise using wood blocks between the rack and the jaw
240. verse switch 16 as shown 3 Position the Forward Reverse switch 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 Install seat support See Seat Support Installation on page 4 13 Access Panel Access panel 6 is secured to the rear underbody 4 with two expanding screws 7 Figure 4 8 Page 4 11 When replacing the panel tighten screws 7 enough to hold the panel in place Rear Underbody Removal 1 Remove four screws 5 attaching the rear underbody 4 to vehicle Figure 4 8 Page 4 11 2 Lift the rear edge of the rear underbody 4 until the front portion slides out from beneath the front under body Remove the rear underbody from the vehicle Rear Underbody Installation 1 Install rear underbody 4 on the vehicle Figure 4 8 Page 4 11 Install four screws 5 to secure the underbody to its vehicle Tighten screws 5 and 18 to 3 7 ft lb 5 N m CANOPY TWO PASSENGER See General Warnings Section 1 Page 1 1 CAUTION e To prevent damage to the canopy do not remove the canopy supports 3 7 and 10 from the vehicle without first removing the canopy 1 Figure 4 12 Page 4 17 TWO PASSENGER CANOPY REMOVAL 1 Remove the two nuts 9 and two bolts 8 from the canopy 1 and each front canopy support 7 and 10 Figure 4 12 Page 4 17 Remove the nuts 5 and bolts 4 from the canopy 1 and each rear support 3 Lift canopy 1
241. wer should also be checked periodically If charger cannot remain plugged in or AC power will not be available during extended storage discon nect the batteries for storage See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 CAUTION e Check the vehicle monthly to ensure the charger is operating correctly during storage RETURNING THE STORED ELECTRIC VEHICLE TO SERVICE 1 If necessary connect batteries 2 Fully charge batteries A WARNING e Do not attempt to charge frozen batteries or batteries with bulged cases Discard the battery Frozen batteries can explode 3 Adjust tire to recommended pressure See Section 2 Vehicle Specifications 4 Perform the Pre Operation and Daily Safety Checklist See Section 10 Periodic Maintenance 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 3 3 SECTION A BODY AND TRIM A DANGER e See General Warnings Section 1 Page 1 1 A WARNING e See General Warnings Section 1 Page 1 1 CLEANING THE VEHICLE See General Warnings Section 1 Page 1 1 CAUTION e Do not use detergents or cleaning solvents that contain ammonia aromatic solvents or alkali materials on body panels or seats e Do not allow battery acid to drip on body panels Battery acid will cause permanent damage Wash spilled battery acid from body panels immediately Club Car Precedent vehicles are equipped w
242. wing procedure is provided as a guideline for determining general bearing failure 1 Remove the motor from the vehicle See Motor Removal on page 15b 2 2 Remove the bearing by performing steps 1 through 14 of Motor Disassembly on page 15b 4 3 Use a clean cloth to wipe the carbon dust off of the bearing Inspect the bearing by spinning it by hand and checking for both axial A and radial B play Figure 15b 14 Page 15b 9 4 Replace the bearing if it is noisy does not spin smoothly or has excessive play Check the bearing and replace if rusted worn cracked or if there is an abnormal color change in the metal of the bearing C SHAPED STEEL PLATE Figure 15b 13 Brush Spring Tension Test Figure 15b 14 Bearing Inspection Speed Sensor Magnet Inspection Inspect the speed sensor magnet 24 for rust wear and cracks Figure 15b 15 Page 15b 10 Replace the magnet if necessary 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 15b 9 15B 15B MOTOR MODEL EJ4 4001 a NE TYPICAL 2 PLACES Figure 15b 15 Motor Page 15b 10 men Ei OZO yea Lei D vm SCH Motor Component Testing and Inspection TYPICAL 2 PLACES 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual MOTOR MODEL EJ4 4001 RECONDITIONING THE MOTOR See General Warnings Section 1 Page 1 1 Motor reconditioning must be performed by a qualified motor repair
243. with local state and federal regulations AXLE BEARING AND SHAFT See General Warnings Section 1 Page 1 1 AXLE SHAFT Axle Shaft and Oil Seal Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 Place chocks at the front wheels Loosen lug nuts on rear wheels and lift the rear of the vehicle with a chain hoist or floor jack Place jack stands under the axle tubes to support the vehicle See WARNING Lift only one end in General Warnings Section 1 Page 1 2 Remove the rear wheel and brake drum See Section 6 Wheel Brake Assemblies and Section 8 Wheels and Tires Use 90 internal snap ring pliers to remove the internal retaining ring 6 from the axle tube Figure 16 5 Page 16 3 See also Figure 16 1 Page 16 2 Remove the axle retaining ring and bearing assembly by pulling the axle straight out of the housing If necessary remove the axle oil seal and adapter ring 6 1 Use a bearing puller CCI P N 101641 7 to remove the axle seal and adapter ring from the axle tube Figure 16 2 Page 16 2 See following CAUTION and NOTE CAUTION e 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 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 16 1 TRANSAXLE TYPE G Axle Bearing and Shaft
244. y Wire on page 11 33 e Red wire at the charger receptacle See Test Procedure 12 Voltage at Charger Receptacle Red Wire Socket on page 11 33 TEST PROCEDURE 11 ONBOARD COMPUTER GRAY WIRE See General Warnings Section 1 Page 1 1 1 With batteries connected and the DC cord disconnected pull back on the boot on the gray wire connec tion at the OBC Figure 11 18 Page 11 33 Using a multimeter set to 200 volts DC connect the red probe to the positive post of battery no 1 and black probe to gray 16 gauge wire at the OBC con nection Reading should be approximately 48 volts If reading is zero volts replace the OBC PROBE HERE D REAR OF OBC Figure 11 18 OBC Connections 2 If the reading in step 1 is 48 volts plug 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 wire circuit in the OBC has failed Replace the OBC TEST PROCEDURE 12 VOLTAGE AT CHARGER RECEPTACLE RED WIRE SOCKET See General Warnings Section 1 Page 1 1 1 With batteries connected DC cord disconnected and using a multimeter set to 200 volts DC place the black

05 Electric Service Manual

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