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1. Figure 7 8 Remove 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 n 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 11 12 13 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
2. ecm ios 12 8 EA Ee B od ee tet epe ee EES m gei E 12 10 Solid State Speed Coritroller 5 n nde ere e xe Cete eedem eese Maeda deed es 12 11 eidele eM 12 12 Onboard Computer OBC EE 12 13 Charger Receptacle ccoo ad be senna siae Fete dude va ud Ede dae Eun Te Fea Ve Haee go 12 13 SECTION 13 BATTERIES General Information miii eicere idee ra aene nea dea oe tando taa dde eee eee 13 1 Battery Replacement iii ed aee Ee CES 13 1 Battery Care P 13 2 Preventive Maintenance osioon e ri aa eon dense EEE AA ESE nne nis 13 2 Self Discharge EE 13 3 Electrolyte Level nut i epe iet ete og a e ettet iens 13 3 Mineral COmMent SP 13 4 Vibrations Damage 212 Emm 13 4 Battery Charging EE EE 13 4 Charger Shuts Off After 16 Hours 0ooooccccocccccccoooancnccononcnncconnnnnnncnnnn ene nnn nennen nennen nennen 13 5 Deep Bischarge iter adit e i tede den a dae e t EE E dea 13 5 Early Excessive Discharging earma sarin aa E EE T A A a 13 5 INGOMING E LEE 13 5 Fliget Rotation mS 13 5 Numbering Vehicles and Chargers coocooccccninoccccnoncnoncncnonnonnnononnn nono nonnn nennen nn nr rn nnne ener nnne nnns 13 5 Battery Troubleshooting Chart sresreraor nnr a A T EE Ea E A S E nennen nnne trennen 13 6 Battery Testing eet em hte Ur he AR eR e x n e ER EUM ERGO REED et Deer REA 13 7 Battery Charger Test eee tica
3. Figure 11 2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual o8 10 BLACK RECEPTACLE QA 0 RED 6 PIN GROUP CONNECTOR oN BOARD COMPUTER 6 BLACK wienn N NAI SS o E e d OWL G FO FNY JO 6 BLACK TERMINAL SPADE TERMINAL NOTE SOME WIRING COMPONENTS SHOWN ARE OPTIONAL ACCESSORIES Precedent Electric Vehicle Wiring Diagram Page 11 3 ELECTRICAL SYSTEM AND TESTING USED WHEN THERE ARE LIGHTS BUT NO TURN SIGNAL Ee NORMALLY OPEN MOMENTARY PUSH BUTTON FOR HORN 16 ORANGE 16 BLUE WHITE 16 WHITE amp LS x gt SC B CONS UNIT red 16 BROWN 3H6 YELLOW 16 BLACK va a T 16 YELLOW A SONIC 16 BROWNWHITE WELD A PIN CONNECTOR 16 BLACK Wiring Diagrams 16 BLACK 16 ORANGE 16 GREEN 16 BLUE 16 ORANGE 16 GREEN 16 GREEN 16 RED 16 BLUE WHITE 16 RED 16 RED 16 BROWN 16 BLUE WHITE URN SIGNAL 16 GREY SWITCH 16 WHITE 16 WHITE 16 YELLOW 16 WHITE 16 YELLOW 16 BROWN WHITE 16 BROWNIWHITE NORMALLY OPEN MOMENTARY 16 GREY BLK PUSH BUTTON FOR HORN USED WHEN THERE ARE TURN SIGNALS Figure 11 3 Precedent Electric V
4. 0 67 liters SAE 30 WT API technician only O Class SE SF or SG Oil or higher every 100 hours of operation or 200 rounds Pedal group O SEH Performance Dry Multi Use ubrican of golf 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 See General Warnings Section 1 Page 1 1 A WARNING See General Warnings Section 1 Page 1 1 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 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 slo
5. 5 Loosen jam nuts 4 and 5 on each side of turnbuckle 6 6 Nut 4 has a left hand thread Figure 5 1 Pedal Group Access 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 5 1 EN ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group TYPICAL TYPICAL 2 PLACES 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 CR 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 hel
6. 7 and sleeves 8 and 9 in the control arm and replace them if necessary CONTROL ARM INSTALLATION 1 Install the control arm in reverse order of removal Tighten the control arm bolts 11 and 19 to 20 ft Ib 27 N m Figure 7 18 Page 7 15 Tighten three rack and pinion mounting bolts 17 to 22 ft Ib 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
7. and 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 Read Section 1 Safety before attempting any service on the vehicle 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
8. 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 EE S P EE E EEA E ATTE EE EE 8 2 TA Retmemalk can a ee eege EE 8 2 RI EE 8 2 Tire Installation EIE 8 3 SECTION 9 REAR SUSPENSION General Information RR 9 1 ee e 9 1 Shock Absorber Removal and Inspection cccccccccccecececeeceeeeeeeeseeeeeaeseessaasaeaeesseeeeeseseeeeeseeees 9 1 Shock Absorber Installation rronin e rE e A A EEEE E E ERE nnne 9 1 Leaf Springs Two Passenger Vehicles ooooocnnnccccccnnnicocincnnoccnnanonannnnnc nano nnnrnnnn rn cnc nemen nnne nenne 9 1 Leaf Spring Removal Two Passenger Vehicles ooooooconiciccconccccccccncccconnnnnnnnncncnnnnnnnnnnnannnnnnnos 9 1 Leaf Spring Installation Two Passenger Vehicles ooooooncinnccncncccccnnncccconanananoncnncnnnnnnnannnnnnnnnnnos 9 4 Leaf Springs Four Passenger Vehicles sssssssssseeeeenn mme nennen nennen 9 4 Leaf Spring Removal Four Passenger Vehicles ssssssssssssseeeee 9 4 Leaf Spring Installation Four Passenger Vehicles ooococononccocccnccnnncccccccnnnnononncnnnnnncnnnnannnnnnnncnnnos 9 6 SECTION 10 PERIODIC MAINTENANCE General Information eesssssssssesssssene ee ene nmene non cnn nnnn cano nnns nares essa sess nasa ss sanas sess sss anna 10 1 Periodic Service Schedule emir oe ded al
9. AND FRONT SUSPENSION Front Wheel Bearings and Hubs FRONT WHEEL BEARINGS AND HUBS See General Warnings Section 1 Page 1 1 NOTE The front wheel bearings are pressed into the spindle and are not serviceable If excessive free play is detected the entire hub should be replaced FRONT WHEEL FREE PLAY INSPECTION 1 2 Raise the front of the vehicle 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 c RON 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 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 BON o NOA 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 b
10. 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 1 2 Remove screws 2 from top of retainer 1 Figure 4 4 Page 4 6 Remove screw 4 from lower rear 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 1 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 Ib 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 Ib 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 vehi
11. 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 Ib 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 Liftthe 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 To prevent damage to the canopy do not remove the canopy supports 3 7 and 10 from the vehicle with
12. Spring is under tension Use caution when working with springs 1 With the pedal group removed from the vehicle and debris shield removed remove the accelerator return spring assembly 2 Toinstall 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 EX ACCELERATOR AND BRAKE PEDAL GROUP SIOP PPOSITE SIDE VIEW EN Figure 5 4 Brake Pedal Page 5 5 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual EN 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 Ib 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 peda
13. a crisscross pattern until they are snug 2 Lower the vehicle and finish tightening lug nuts using 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 IE 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 If a 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 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 r
14. 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 power 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 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 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 4 BODY AND TRIM A DANGER See General Warnings Section 1 Page 1 1 A WARNING See General Warnings Section 1 Page 1 1 CLEANING THE VEHICLE See General Warnings Section 1 Page 1 1 CAUTION Do not use deter
15. heat gun back and forth over the affected area until the streak fades 3 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 Holding the heat gun too close to the 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 1 Hold a heat gun 12 inches 30 cm away from the affected area with the gun on its lowest heat setting 2 Periodically remove the heat gun and bend the body using a push block in the opposite direction of the deformation 3 Continue heating and bending the body until the original shape returns Under no 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 1 Thoroughly clean the affected area using a strong non abrasive detergent and hot water then clean with Ultra Kleen9 Solvent Cleaner to remove any oil based contaminants 2 Lightly buff imperfection with a clean soft cloth or buff pad Do notuse any kind of rubbing abrasive com pound on body assemblies 3 Wax the entire body part to restore luster and weath
16. 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 Atthe 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 Ib 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 See General Warnings Section 1 Page 1 1 A WARNING 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 Warnings Sectio
17. 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 controller 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 b
18. is very important 3 Apply a liberal amount of tire mounting lubricant soap and water solution to both tire beads and rim flanges 4 Install the tire on the rim from the valve stem side If there is no tire machine available use a rubber mallet and tire iron 5 Remove the valve core and position tire so that both beads are on the rim flange narrow bead seats 6 Place tire and wheel assembly against wall in upright position and push it against wall while inflating tire to 30 35 psi 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 IE WHEELS AND TIRES Tires Figure 8 2 Inflate Tire Page 8 4 2005 Precedent IQ System Electric Golf Car Maintenance and Servic
19. rack in a vise using wood blocks between the rack and the jaws of the vise to protect the rack from damage Tighten the ball joints to 60 ft lb 81 N m 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 Ib 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 Ib 0 8 to 1 7 N m If measured resistance is not 7 to 15 in Ib 8 to 1 7 N m adjust the screw 13 until correct setting is achieved Tighten the nut 14 to 28 ft Ib 38 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 Ib 27 N m Figure 7 5 Page 7 6 Page 7 8 2005 Precedent IQ System Electric Golf Car M
20. 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 shown Tighten the hardware to 124 in Ib 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 Ib 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 Ib 13 6 N m Tighten the four bolts 2 installed in step 1 2 to 18 ft Ib 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 See General Warnings Section 1 Page 1 1 A WARNING 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
21. 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual
22. 6 SECTION 7 STEERING AND FRONT SUSPENSION General Information Steering Wheel Steering Wheel Removal Steering Wheel Installation AA Steering Column Steering Column Removal 1 intei nente eet eal eae a dre eae Roseto etr re EPA eee Steering Column Installation ereiaro a Ea A r nnne nnns Rack and Pinion Rack and Pinion Removal Rack and Pinion Disassembly ssostni alaa aa a ea ee nennen nnne nnne Rack and Pinion Assembly sssssssssssssseeseeeeeeeneen nennen nennen nennen nnne n sent rn rra rennes Rack and Pinion Front Suspension Lubrication Wheel Alignment nstallation it is Front Suspension Components raserer enra ead aee non nn adea nn nena aet Ea ee iane eea Ra nennt Tie Rod End Removal Tie Rod Installation beat Spring Removal stees ner HR di eee Leaf Spring Installation Kingpin and Steering Spindle Removal Kingpin and Steering Spindle Installation Control Arm Removal Control Arm Installation Shock Absorber Removal Shock Absorber Installation Front Wheel Bearings and Hubs ssssssssssssssssssesssssem e eene enne nnn nnne nnn nnnm Front Wheel Free Front Hub Removal Hub Installation Play Inspection SECTION 8 WHEELS AND TIRES General Information Wheels Wheel Removal Wheel Installation 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual 74 7 1 7 1 7 2 7
23. 9 Motor E le KEE 15a 10 Motor uf UE le WEEN 15a 12 Motor SpeediSensor oco ce licita 15a 15 SECTION 15B MOTOR MODEL EJ4 4001 General Informatlon tati eH emer e tet eine pete i 15b 1 leegen ere EE 15b 1 External Matar Testing sa ecrit E ii 15b 1 MOLOE EE 15b 2 Motor Removal p u u 15b 2 Motor Disassembly x tt RH EE 15b 4 Motor Component Testing and Inspection ssssssssssssssseseeeeeenneee ener 15b 6 Armature Inspection and Testing sisi oia ao i aaaea aaaea a a Or aa a ara nre nennt 15b 6 Motor Frame and Field Windings Inspection ooocccnnnnnnnncnonoccncnnnccncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 15b 8 Motor Brush Spring and Terminal Insulator Inspection 15b 8 Reconditioning the Motor ek PIE ete abet eM attigi gedet reU 15b 11 Motor Assembly oid ro o 15b 11 Page viii 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Motor Installation 15b 13 SECTION 16 TRANSAXLE TYPE G fleit te EE 16 1 Axle Bearing and Shaft isis er teet e ed tpe e een t ne tos 16 1 Axle Shall octet cates e 16 1 Axle Bearing oe nre cbe esi buses UN e e Ln esM Ati Qe 16 4 Transaxle a eatin cei tte dE Eae ben ee eases aede a dia 16 5 Transaxle e VE 16 5 Transaxle Disassembly Inspection and Assembly sssssssssssssseeemmn 16 7 Transaxle Disassembly and Inspection oooocooncnccccoccccnncccccoconnnonnnnn
24. ARNING 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 Ib 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 forward jam nut 1 is a le
25. BRICATION Two grease fittings are provided one in each spindle housing Lubricate these fittings at the recommended interval with the proper lubricant See Periodic Lubrication Schedule Section 10 Page 10 3 CAUTION 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 a 7 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 31 N m Then roll the vehicle forward one full tire revolution and recheck the camber See als
26. Club Car Maintenance 2005 And PRECEDENT Service am 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 Itis 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
27. D TRIM Rear Body Four Passenger Vehicles TYPICAL 10 PLACES 6 PLACES 2 rca 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 vehicle 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 Ib 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 da ae A eem TYPICAL PLACES Figure 4 11 Seats Four Passenger Vehicles REAR BODY COMPONENTS FOUR PASSENGER Rear Beauty Panel Removal a e O N gt Remove seat support See Seat Support Removal on page 4 13 Remove four screws 13 attaching the rear beauty panel 12 to the fuel bucket Figure 4 8 Page 4 11 Remove two screws 14 and remove the Forward Reverse switch housing 15 from vehicle 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
28. Discard the battery Frozen batteries can explode A CAUTION Batteries in low state of charge will freeze at low temperatures 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 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 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
29. ENSION 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 APPEARANCE 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 SUSPEN
30. M TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL TYPICAL 4 PLACES 7 Backrest and SAM Figure 4 Page 4 9 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual BODY AND TRIM Rear Body Two Passenger Vehicles BACKREST AND STRUCTURAL ACCESSORY MODULE SAM 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 3 over its mounting holes and secure with four screws 4 Tighten screws to 53 in Ib 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 Ib 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 hol
31. OEA NSERIES Two Passenger Canopy Removal sssssssssseseeeeeeen eene n nennen nennen nnne enne Two Passenger Canopy Installation essere nennen NA Four Passenger Canopy Removal ssssssssssssssssseeeeeeee nenne eren nennen nennen Four Passenger Canopy Installation ssssssssssssseememmenenennne nemen SECTION 5 ACCELERATOR AND BRAKE PEDAL GROUP REI EE Brake Ret rn Spring e alieni iac epe dd Re RR Yee dmn aa ales Pawl ASSEMDIW ek LET Accelerator Return Spring ossessi reoaine ae ran etene aea ae a ae eR A ennt nnn n nnn aiaa nsns nennen Pedal Group Installation i rU o e a debes td Da ar a SECTION 6 WHEEL BRAKE ASSEMBLIES General Information EE Brake Shoe Removal scrire a e a AA Brake Assembly Cleaning cc ccccecccceeesecneeeeeesneecesendececeetesaaeceeeeneceeedseeeeeedensneeteneneceeseeeeeneeteeeteees Brake Shoe Installation e TREE pls i eget ce eor d edd de MIU Tek qe EE Brake Cable Equalizer Adjustment ssssssssssssssssssssessseneneeeee eene nennen enne nnn Brake Cluster Removal and Installation ssssssssssssssssseseeeeeeennneneeeemeeeen enne Brake Cluster InstallatiOri 5 edere et e A ederet eet Ete e Brake Cable Removal and Installation eseesesesesen mener r nena Page iv 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual 5 1 5 1 5 3 5 3 5 3 5 4 5 4 5
32. OWN LEFT Wiring Diagrams 10 AMP FUSE 12 BLUE 12 BLUE 18 BRN E HB RED TAILLIGHT 16 BLKWHT 18 BLK 16 BROWN V 16 BROWN 18 BRN RIGHT 16 YELLOW DS TAILLIGHT 12 BLUE A D o E UO 12 BLACK 12 BLACK 16 TAN SONIC WELD 16 RED 18 ORANGE 18 BLUEMWHITE SS gm 16 BLUE BRAKE LIGHT SWITCHES 16 BLK WHT 16 GREEN 18 PURPLE 18 BROWNWHITE 18 WHITE 18 WHITE 16 RED 16 PINK 16 PINK SONIC WELD 16 RED 18 RED 16 RED SOLENOID Me WELD 6 YELLOW 18 ORANGEMHITE 18 REDIGRN e a S YATIA BL Q38 NH9 814 BAM 81 18 BROWNMHITE 18 BROWNMHITE 18 LT BLUE A BULLET CONNECTOR E Es 10 YELLOW REVERSE No PRE CHARGE RESISTOR e 10 YELLOW VA FORWARD 18 BLUEMHITE 3LIHM 8 18 BLUWHT 18 YELLOW 18 LT BLUE M 18 ORANGEMHITE 6 WHITE 2 PIN T CONNECTOR 3H8 BLUE SONIC K WELD 18 GREEN A2 10 BLUE JE F1 F2 MOTOR 18 GREEN 18 PURPLE 18 YELLOW 18 WHITE BLACK 3 PIN CONNECTOR PIN 14 LT GREEN TO MOTOR SPEED SENSOR OUTPUT PIN 15 RED
33. Panel 7 LS M AS E MU if 4 E WM e Sy Sa LESS TYPICAL 2 PLACES 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 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 N m 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 nera TRIM CLIPS 4 PLACES
34. SE Instrument Panel Installation Floor Mat and Retailers ote e Edel RUE e EE RE eh ici Floor Mat Retainer Removal nian aA EAE a T a A A a EAE Floor Mat Retainer Installation stion a a a a a a a a a aas 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual 3 2 3 2 3 3 3 3 4 1 4 1 4 2 4 2 4 2 4 2 4 2 4 4 4 4 4 4 4 4 4 4 4 4 4 6 4 6 4 7 4 7 Page iii Kick Plate and Charger Receptacle Bezel ssssssssssssssssesseeeeeeenennmmemeenen enne nnn Kick Plate and Charger Receptacle Bezel Removal sss Kick Plate and Charger Receptacle Bezel Installation ssssseeeeeese Rear Body Two Passenger Vehicles 0 cccceeeeeeeeeeeeeeeeeeeeeeeeeceaaeeeeeeeeeeeseecccccneaeeeeeeeeeteeteneneenees Universal Accessory Mounting ssssssssssssssssseeeeeneeeeeee nennen nennen nnne nnn n nen n nennen nnns Backrest and Structural Accessory Module SAM sss Rear Body Components Two Passenger cccccceeeeeeeeeeeneeeceeeeeeeteeeecccccaeeeeeeeeeeeesesenanaeeeeeeees Rear Body Four Passenger Vehicles c ccececceceeeeeeeeeeeeeeenaeeceeeeeeeeeseecccaaeeceeeeeeeeteeeeeennsnees Seal e coeant neg tee eg eae eed ee EE FOOR DOCK cotorra iodo Rear Body Components Four Passenger coocoocccccccccccccononononnnnnncnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnncnnnnnne Canopy Two Passenger userei eiin an re OER RNA AALA
35. SION APPEARANCE OF SCORECARD HOLDER MAY BE DIFFERENT THAN THAT SHOWN TYPICAL 2 PLACES NOT REQUIRED FOR SOME SCORECARD HOLDERS Ss 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 2 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 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 Ib 25 N m 4 Tighten universal joint bolt 11 to 18 4 ft Ib 25 N m Verify bolt 12 torque is 18 4 ft Ib 25 N m 5 Install front bumper dash assembly dash insert and instrument panel See Section 4 Body a
36. TE The front measurement must be less than the rear measurement 2005 Precedent 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 Ib 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 2 Remove the retaining pins 15 and retaining nuts 14 3 Lift male thread of tie rod from t
37. TO HIGH SIDE OF MOTOR SPEED SENSOR PIN 16 BLUE TO FORWARD amp REVERSE SWITCH REV PIN 8 WHITE TO FORWARD 8 REVERSE SWITCH FOR PIN 7 ORGIWHT TO LOW SIDE OF REVERSE BUZZER PIN 6 GREEN TO ACCELERATOR LIMIT SWITCH M 3 PIN 1 Ko CONNECTOR ep CONTROLLER 10 ORANGE Y 6 GREEN N3349 17 814 10 BLACK 18 BLACK WHITE 18 LIGHT GREEN 18 RED 6 BLACK PIN 13 BLKWHT TO LOW SIDE OF MOTOR SPEED SENSOR PIN12 BLUNHT TO LOW SIDE OF SOLENOID COIL PIN 11 OPEN PIN 10 TAN TO KEY SWITCH SONIC WELD PIN 9 GRAY AUX 9 1 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 5 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 12 BLUE Wiring Diagrams 18 WHITE 16 PINK gerep DIODE tg BLUE Y TOW SWITCH 16 BLUE e 18 RED 18 BROWNMHITE 318 WHITE 18 YELLOW 18 BROWN WHITE 10 BLACK 18 LT BLUE 8LTBLUE 18 YELLOW 18 RED POSITION CONNECTOR 10 BLACK
38. aintenance and Service Manual STEERING AND FRONT SUSPENSION RACK AND PINION INSTALLATION Rack and Pinion 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 Ib 30 N m 5 Install the tie rod ends 3 into the left and right hand spindle tabs 4 and then install the retaining nuts 2 Figure 7 4 Page 7 5 See following WARNING A WARNING 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 Td SOCKET DUST SEAL UH Ti Figure 7 11 Install Ball Joint DEEP WELL SOCKET 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 LU
39. al 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 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 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 difficult the
40. and Service Manual Page 6 5 EN WHEEL BRAKE ASSEMBLIES Brake Shoe Installation 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 ER SILVER SPRING Note that the silver spring
41. attery condition 2 monitors the number of energy units used by the vehicle 3 determines the number of energy units required to recharge the batteries and shuts the charger off when this number is reached 4 determines when to activate regen erative motor braking 5 locks out vehicle movement while the 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 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
42. bly 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 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 10 11 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 the leaf spring Figu
43. brake shoes may need to be adjusted vertically in the mounting slots 9 Afterthe drumis 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 ui pe 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 Eo 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 x 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 Ib 17 5 N m Figure 6 18 Page 6 8 then tighten the front jam nut to 13 ft Ib 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 mechanism A W
44. cle 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 1 Position the kick plate 2 on the vehicle and secure with three screws 1 Figure 4 5 Page 4 8 Ensure 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 3 to secure the rear beauty panel Tighten screws to 3 7 ft Ib 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 ATTACHMENT POINTS Figure 4 6 Universal Accessory Mounting Page 4 8 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Rear Body Two Passenger Vehicles BODY AND TRI
45. 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 SYSTEM 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 se
46. d in place with screws 1 and washers 2 Figure 5 4 Page 5 5 When shields are replaced tighten screws 1 to 53 in Ib 6 N m BRAKE RETURN SPRING A CAUTION 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 EN 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
47. dure See following CAUTION A CAUTION When positioning the spring on the transaxle be sure to insert the locating bolt on the spring in the locating hole in the transaxle saddle 2 Tighten the nuts on the U bolts to 25 ft Ib 34 N m 3 Tighten nuts 2 on spring mounting bolts 17 to 15 ft Ib 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 See General Warnings Section 1 Page 1 1 A WARNING 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 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 shou
48. e Manual SECTION 9 REAR SUSPENSION A DANGER See General Warnings Section 1 Page 1 1 A WARNING 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 Toremove 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 whee
49. e dee ee ed Eel eddie aita ee ieee de tthe ei eee init 13 7 OnsCharge Voltage Test iii ce eed dee AE ee dt da ee deu ca Lan e EUER Laos 13 7 Hydrometer S 13 7 Discharge Test iaa E 13 9 Battery Troubleshooting Examples ccccceeeeeeeeeeeeceeeeeeeeeeeeeeeececeeaeeeeeeeeeseeseecnnaeeeeeeeeeeteetes 13 11 Battery Storage t o i e e tuse Ae ede te E e tiat tie 13 12 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page vii Charging a Battery Pack that has Low Voltage eene 13 12 SECTION 14 BATTERY CHARGER SECTION 15A MOTOR MODEL 5BC59JBS6365 General lte E en NEE 15a 1 Motor e uer Le BEE 15a 1 External Motor Testi reiini dias 15a 1 ero A P KA 15a 3 Motor Component Testing and Inspection ssssssssssssssssseseeeeeneeeem eren 15a 5 XEM cn 15a 5 Field Windings Inspection sessssssssssssssseeeeeneeeeene nennen nn sn nnn nnn nnne enteen Enne 15a 6 Motor Components eebe ce E epa eed E Rs 15a 7 Bearing Inspectlom erheben Mu 15a 7 Bearing Removal 20 2 e dte dotar deux ede Eee Bd Pra ea ar ege a aUe Ele ska ae e Rave pa deua en 15a 9 Bearing Installation re o eU eruere tii etd 15a 9 Speed Sensor Magnet Inspection cccecceeececeeneeeceeeeeeeeeeeeceaaeeceeeeeeeeeseeeceneeeeeeeeeeeeeeeeesnneaeees 15a 9 Speed Sensor Magnet Removal sse enne nn nennen 15a 9 Speed Sensor Magnet Installation 15a 9 Reconditioning the Motor A 15a
50. eed 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 Electrical 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 s Brakes Dual rear wheel self adjusting brakes with cast iron drums and single brake pedal with automatic release 7 park brake BODY CHASSIS Frame Chassis Aluminum and composite Front and rear body Dupont SurlynO Reflections Body finish High gloss molded in color Tires 18 x 8 5 8 tubeless 4 ply rated DIMENSIONS WEIGHT Overall length 32 om 264 on Overall width S 199 c8 Overall height with canopy ra em 100 um Overall height at steering wheel io on 192 om Wheelbase 168 om 168 om Ground clearance Gres LORD Front wheel tread 88 em GC Vehicle Specifications continued on next page 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 2 1 Two Four SPECIFICATIONS Passenger Passenger Electric Electric Vehicle Vehicle Rear whe
51. ehicle Accessory Wiring Diagram 888888860 Page 11 4 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual ELECTRICAL SYSTEM AND TESTING HEADLIGHT ASSEMBLY 16 GREEN 16 BLACK A BLUE CN X 16 ORANGE 16 BLACK SONIC A WELD 18 ORANGE 14 BLACK 16 ORANGE m 16 ORANGE 16 BLACK WHITE Wiring Diagrams 12 BLACK 16 GREEN 14 YELLOW 16 BROWN 14 YELLOW 16 RED 316 BLUE WHITE LIGHT SWITCH e e e e e DC DC CONVERTER 20 AMP FUSE CM 18 BLUEWHTE 16 YELLOWMHITE A2 BLACK 16 PURPLE CONNECTS TO MAIN HARNESS SEE FIGURES 11 1 AND 11 2 16 WHITE 16 BLACK WHITE 16 BROWN 16 YELLOW 16 WHITE 16 YELLOW 12 BLUE 12 BLACK 16 BROWNMWHITE 16 GREENWHITE 16 BROWNWHITE 16 GRNWHT SONIC WELD 18 ORANGE 18 BLUE WHITE 18 GREEN 18 BLUE WHITE 18 BLUEMHITE 18 BROWN D DIODE SONIC WELD 18 ORANGE 18 BLUEWHT BRAKE LIGHT RELAY 6680088888600 6009900000000 SONIC WELD NOTE SOME WIRING COMPONENTS SHOWN ARE OPTIONAL ACCESSORIES Figure 11 4 Preced
52. el tread 96 om 96 eim Weight standard electric vehicle with canopy with batteries 388 Vi 440 Vi Weight standard gasoline vehicle with canopy with battery without fuel Forward speed 12 15 mph 19 24 km h Curb clearance circle diameter 528 em n en Standard seating capacity 2 4 LIQUID CAPACITIES 22 oz 22 oz Transaxle 67 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 See General Warnings Section 1 Page 1 1 A WARNING 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 Pre Operation and Daily Safety Checklist Controls and Indicators Driving Instructions Towing Transporting on a Trailer Subsequent Owner Registration Warranties SERIAL NUMBER IDENTIFICATION The serial number of the vehicle is printed on a bar code decal mounted on the passenger side inner dash Figure 3 1 NOTE Always have the vehicle serial number available when ordering parts or making inq
53. emoval e WHEEL BRAKE ASSEMBLIES Figure 6 4 Self adjusting Wheel Brake Assembly Page 6 3 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual e 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 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 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 EN 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 wo
54. emove the 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 Rack and Pinion STEERING AND FRONT SUSPENSION Figure 7 5 Steering Gear 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 7 6 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 MU i Figure 7 6 Remove Dust Seal Figure 7 7 Pinion Snap Rings Leg PRESS RAM PINION GEAR
55. emoved from the rim by hand TIRE TOOL UPPER TIRE BEADS TIRE BEADS POSITIONED IN RIM WELL RIM LOWER TIRE BEADS BCE VALVE STEM SIDE UP a 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 EB NOTE Anair 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 ofthe 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 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
56. ent Electric Vehicle Accessory Wiring Diagram 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 11 5 ELECTRICAL SYSTEM AND TESTING Wiring Diagrams OPTIONAL BATTERY INDICATOR a mn 9 PIN CONNECTOR SONIC WELD CONNECTS TO MAIN HARNESS SEE FIGURES 11 1 AND 11 2 18 RED 16 BLUE 16 GREEN RED 18 BLACK YELLOW 18 BROWN WHITE 18 BROWN WHITE 18 ORANGEMHITE 18 RED 18 YELLOW 18 GREEN REVERSE BUZZER 18 BLACK e MI M PROGRAMMER PLUG 18 ORANGE 18 BROWNMHITE WARNING LIGHT 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 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
57. eplace if necessary Front wheel alignment and 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 Lubricate all rotating joints See Periodic Pedal group Lubrication Schedule on page 10 3 General Vehicle Check for loose hardware tighten if necessary A WARNING 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 E PERIODIC LUBRICATION SCHEDULE REGULAR INTERVAL SERVICE LUBRICATION RECOMMENDED LUBRICANT Semiannually by owner Ch tacl WD 40 or trained technician i c o every 50 hours of Brake s ystem per maintenance Dry Moly Lube CCI P N 1012151 operation or 100 rounds and service manual O white lithium grease NLGI 2 of golf Front suspension two fittings O Chassis Lube EP NLGI Grade 2 Annually by trained Check fill transaxle to plug level 22 oz
58. er 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 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 4 Remove the five screws 8 and lift the brow and fascia assembly 4 from the front underbody 5 Remove the five screws 7 to separate the front fascia 6 from the brow 5 FRONT BODY INSTALLATION 1 Install fascia 6 to brow 5 with five screws 7 Tighten screws to 3 3 ft lb 4 5 Nm Figure 4 1 Page 4 3 Install brow and fascia assembly 4 to front underbody
59. erve 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 1096 liquid dish soap and warm water applied with a soft damp cloth is rec 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 9096 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 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 Hold a heat gun 12 inches 30 cm away from the affected area with the gun on its lowest heat setting 2 Slowly wave the
60. es 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 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 Q9 xcd 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 TYPICAL 4 PLACES TWO PASSENGER VEHICLES ONLY TWO PASSENGER 8 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 sw
61. esidual 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 Ib 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 Be sure retaining ring is properly seated in groove If ring is not properly installed the axle assem
62. ft 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 ES 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 Before installing axle shaft clean any r
63. gents or cleaning solvents that contain ammonia aromatic solvents or alkali materials on body panels or seats 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 with 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 Use of leveling or rubbing compounds will permanently dull finish of vehicle 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 pres
64. he 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 1 1 After disconnecting the batteries wait 90 seconds for the controller capacitors to discharge Do not leave children unattended on vehicle Place Tow Run Remove negative switch in TOW cablefirst 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 Passenger Passenger Electric Electric Vehicle Vehicle POWER SOURCE Drive motor Direct drive 48 volts DC shunt wound 3 2 hp 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 sp
65. he hole in the spindle tab 4 Remove the tie rod ends from the steering 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 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 oa F WN 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 Re
66. ies 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 solenoid 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 mot
67. ighten the lock nuts to 50 in Ib 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 Ib 3 5 N m At the front supports 7 and 10 tighten the four bolts 11 to 18 4 ft 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 Ib 4 6 N m Page 4 18 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual BODY AND TRIM Canopy Two Passenger c O TYPICAL aD 4 PLACES cJ TYPICAL P ec 4 PLACES 16 ONA _ Teea 2 PLACES 2 PLACES E SL ZC LZ er CA TYPICAL 4 PLACES TYPICAL 2 PLACES SEATS REMOVED FOR CLARITY 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 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 m o N Remove the two nuts 12 two bolts 11 and space
68. inding side play or any indication of rough spots during rotation Install the dust cap 12 using a rubber mallet and tapping lightly around the edge of the cap Repeat the procedure for the opposite wheel Install wheels and finger tighten lug nuts 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 DANGER See General Warnings Section 1 Page 1 1 A WARNING 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 Keep tires properly inflated See Section 2 Vehicle Specifications Keep lug nuts properly tightened Keep the front end aligned and adjusted A WARNING 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
69. is mounted with the coils to the side of the adjustment lever spring A Oc 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 e 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 SHO TRAILING Figure 6 15 Install Leading Shoe Figure 6 16 Check Shoe Positions 6 Place a flatblade 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 to damage the se
70. it must be replaced Inspect the bushings 4 If the bushings are worn or damaged remove them and press in new ones KINGPIN AND STEERING SPINDLE INSTALLATION Inspect all parts and replace them as necessary 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 Ib 23 N m 3 Install the wave washer 6 on the kingpin 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 EH Ai RB o Ju Inspect the bushings
71. itch 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 Ib 2 3 N m 4 Position canopy support brackets 1 and 2 on vehicle and secure each with one screw 3 Tighten screws to 53 in Ib 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 Liftthe 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 inne
72. itch 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 connector 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 loo
73. l group in vehicle and secure with two screws 2 on the driver side and two screws 1 on the passenger side Tighten driver side screws 2 to 12 ft Ib 16 3 N m Tighten passenger side screws 1 to 5 ft Ib 6 8 N m 4 Usethe 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 Ib 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 See General Warnings Section 1 Page 1 1 A WARNING See General Warnings Section 1 Page 1 1 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 p
74. ld be performed more often than recommended in the periodic 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 e Check electrolyte level Add water if Weekly service by owner Batteries 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 r
75. lign 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 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 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 T
76. ls 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 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 9 1 EN REAR SUSPENSION Leaf Springs Two Passenger Vehicles BRAKE CABLE HANGER MOUNTING l N TYPICAL ON pz EACH SIDE Ze OF VEHICLE TYPICAL 2 PLACES Figure 9 1 Rear Suspension Assembly and Mounting Two Passenger Vehicles Page 9 2 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual REAR SUSPENSION Leaf Springs Two Passenger Vehicles EN Leaf Spring Removal Two Passenger Vehicles Continued A WARNING 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 Rem
77. move leaf spring 13 Check the condition of the urethane bushings 15 and steel sleeves 14 Replace any that are worn or damaged LEAF SPRING INSTALLATION N o oa OQ Install urethane bushings 15 and steel sleeves 14 into leaf spring eyes Figure 7 19 Page 7 16 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 Ib 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 Ib 74 6 N m 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 N D mF D N 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 Remove bolt 8 from bottom of kingpin 7 and remove kingpin Inspect the kingpin and spindle If either is worn or damaged
78. n 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 7 STEERING AND FRONT SUSP
79. nd Trim RACK AND PINION See General Warnings Section 1 Page 1 1 RACK AND PINION REMOVAL 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 gu Reo NU 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 If the 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 R
80. nd when the drums cannot be removed by normal methods proceed to step 7 to minimize damage to the brake cluster and brake compo nents 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 6 1 e 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 BRAKE AXLE TUBE 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 R
81. nimum 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 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 t
82. nnnnnnnnnnnnnnnnnnnnnnnnnnnnneninnnnnnnnnnnno 16 7 Transaxle Assembly titulada ote aee d be imt ed vus uds e ec ERR bue See 16 9 BRETT te EE 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 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 ADANGER indicates an immediate hazard that will result in severe personal injury or death WARNING AWARNING indicates an immediate hazard that could result in severe personal injury or death CAUTION A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result in minor personal injury CAUTION A CAUTION without the safety alert symbol indicates a potentially hazardous situation that could result in property damage GENERAL WARNINGS The following safety statements must be heeded whenever the vehicle is being operated repaired or ser viced Other
83. notice 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 P O 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 TT SECTION 2 VEHICLE SPECIFICATIONS SECTION 3 GENERAL INFORMATION Serial Number Identification o nooccccnnnnncncnnnnaccccnnnncanccnnncconcnnnnnnrn nennen mener nennen nnne nens Safety COMMING 2 6 EE elle EE Preparing the Electric Vehicle for Extended Off Season Storage sssssssssssssss Returning the Stored Electric Vehicle to Service ssssssssssssssssseeeeeee SECTION 4 BODY AND TRIM Front and Rear Body Repair Stress Lines or Streaks iere eripe gees E Rt et RR Den er ud Minor Impact Damage Deformations sse emen Minor Scratches and Surface BlemishesS AA Gouges Punctures Tears Large Scratches and Abrasions ssssssssssssss ErontBOdy iibi berg ds dle ev bein ILE s ed Front B dy e NEE Front Body Installation 2 e Re geet e AE eege Front Bumper A A Ed EE EE Ee Instr umerit Panel ates edet dte ctos Pg De ette ei ona Ebene coh ee Lea e REB er Fass Instrument Panel Removal areik aeaa a E E A E
84. o Figure 7 14 Page 7 11 6 Tighten the hex nut 8 on the adjustment 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 CAMBER ADJUSTMENT EQUAL SPACE BETWEEN TIRES AND FRAMING SQUARES IMPROPER CAMBER ADJUSTMENT Ny SR Kee SS UNEQUAL SPACE BETWEEN TIRES AND FRAMING SQUARES Figure 7 14 Check Camber Toe in Adjustment Front Suspension 7MMDEEP c WELL SOCKET 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 NO
85. ole in the transaxle saddle 2 Tighten the nuts on the U bolts to 25 ft Ib 34 N m 3 Tighten nuts 2 on spring mounting bolts 17 to 15 ft Ib 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 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 3 Remove the tire and wheel assembly on the side from which the spring is to be rem
86. or 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 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
87. os Lob beo oet dotan Lua Dado i ea 10 1 Periodic Lubrication Schedule oocccconcccccnoccccnnnccnnnnanononacanonancnononcncnoncnnnnnncnnnnnacnnnnn nano nnncnnnnnaninnnicnns 10 3 SECTION 11 ELECTRICAL SYSTEM AND TESTING General Information ido ented bes 11 1 Muppe DAS REI ead ih ete veel igs ate teas caret ee 11 2 Troubl shootihig 5 2 TE 11 7 Troubleshooting the Vehicle with the IQDM sssseeennnnnm emen 11 7 Troubleshooting Guide 7 11 8 Troubleshooting Guide 2 cuina e ET meten a a EE 11 11 Test ProCedures 22 oca 11 13 Index of Test lee IEN 11 14 Communication Display Module CDM eene nnne nnns nnne nnns 11 38 Using the CDM to Retrieve Data from the Onboard Computer occcccccccococcccnccncccncinnnanancnnnnnnninnnos 11 39 CDM Troubleshooting Guide sssssssssssssesseeeeeeeeeneenee aa aae a ea 11 40 Page vi 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual SECTION 12 ELECTRICAL COMPONENTS AES CM M 12 1 Battery Warning Eight rre eddie ca 12 3 Forward Reverse Rocker Switch o se aaan aiaa ae reei aaa eo a e aa a A aaaea 12 3 Electronics Module Cover isesi heie a eE i aa aaa reta a EE A Onea Paea N aE aaa 12 5 Tow Ru n Switch scsi eis ee citer RSA aa a E e Fan aided e cu eee aa a av ea de dae 12 6 Motor Controller Output Regulator MCOR ssssseeeneneeennn nennen rennen nnne nnns 12 7 Reverse BUZZ
88. out 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 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 oa o N 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 A
89. ove the tire and wheel assembly on the side from which the spring is to be removed 4 Remove the bow tie locking pin 1 and the clevis pin 2 at the brake lever and brake cable connection and remove cable end 3 from the brake lever Figure 9 3 Page 9 3 Detach the brake cable from the shock mount bracket 4 5 Remove the nut 5 cup washer 9 and rubber 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 aged AS SEEN FROM DRIVER SIDE OF VEHICLE 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 ESA 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 When positioning the spring on the transaxle be sure to insert the locating bolt on the spring in the locating h
90. oved 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 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 o BRAKE CABLE HANGER MOUNTING P REF E MN e REF Lak 28 E e E e go OF VEHICLE Leaf Springs Four Passenger Vehicles EN 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 ESA REAR SUSPENSION Leaf Springs Four Passenger Vehicles LEAF SPRING INSTALLATION FOUR PASSENGER VEHICLES 1 To install the springs reverse the removal proce
91. r 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 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 Ib 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 Ib 6 N m Tighten screws 5 to 44 in Ib 5 N m Tighten bolts 8 and 11 to 124 in Ib 14 N m Figure 4 9 Page 4 13 TYPICAL 10 2 PLACES TYPICAL Ss 8 4 PLACES t 246 T D Ge A i A gt jJ e j TYPICAL 2 PLACES TYPICAL N 4 PLACES amp Figure 4 9 Seat Supports Four Passenger Vehicles 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 4 13 BODY AN
92. re 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 e EN 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 clips on the
93. ressure wet cleaning method per OSHA 29 CFR 1910 1001 GENERAL INFORMATION Precedent Golf Cars are equipped 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 Worn or damaged brake drums cannot be machined to refinish them Replace as necessary NOTE When servicing vehicles with severely worn brake shoes a
94. rk the slide back and forth to ensure that it slides smoothly and easily Install rubber boot onto backing plate A WARNING 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 Usea 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 Usea 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 BOSSES Figure 6 9 Apply Grease On Bosses Figure 6 10 Apply Grease To Brake Shoes and Slots 6 Usea 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
95. rs 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 supports 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
96. rvice 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 SPEED PULSES menu item indicates that speed pulses are OFF when the vehicle is in motion or Diagnostic Menu SPEED SENSOR fault code Loose or disconnected motor speed sensor or broken wire Repair and or connect the three pin connector to the motor speed sensor Loose or disconnected 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 sw
97. se 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 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 batter
98. specific safety statements appear throughout this manual and on the vehicle A DANGER 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 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 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 mi
99. uiries SERIAL NUMBER omer PQ0901 123456 Figure 3 1 Serial Number Decal 2005 Precedent IQ System Electric Golf Car Maintenance and Service Manual Page 3 1 GENERAL INFORMATION Safety Committee SAFETY COMMITTEE If the golf car is to be rented or is part of a fleet we strongly recommend 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 S9911211 Sharp Right S9921211 Steep Hill 9931211 STORAGE See General Warnings Section 1 Page 1 1 A WARNING Turn the key switch OFF remove the key and leave the Forward Reverse switch in the NEUTRAL position during storage This is to prevent unintentionally starting the vehicle or a fire hazard Do not attempt to charge frozen batteries or batteries with bulged cases
100. w the vehicle There are three features of the IQ electrical system which will activate the motor braking function Zero Speed Detect Pedal Down Motor Braking and Pedal Up Motor Braking adjustable with the IQDM P handset Zero Speed Detect This prevents the vehicle from rolling away uncontrolled 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 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 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 FORDC DC CONVERTER ORLIGHTS SEE FIGURES 11 3 and 114 CONNECTS TO 9 POSITION CONNECTOR FOR CONTROLS INIP SEE FIGURE 11 5 Page 11 2 16 WHITE 16 BLACKWHITE 16 BLKWHT e MBBLK 6 BR
101. with five screws 8 Tighten screws to 1 8 ft Ib 2 5 N m 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 panel 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 Ib 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 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

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